A guide rail type rack rail system assembled box-shaped steel track beam and a construction method thereof

Abstract

The application provides a guide rail type rack system assembled box-shaped steel track beam and a construction method thereof, and aims to solve the problems of large processing difficulty, inconvenient transportation and complex on-site installation of the existing track beam. The track beam is composed of two parallel longitudinal beams and multiple cross beams, the longitudinal beams and the cross beams are connected through connecting beams, the inner side of the longitudinal beam is provided with a rack structure including a rack and a channel steel, the rack is engaged with a driving gear of a vehicle to realize walking and climbing. The construction method comprises the following steps: factory prefabrication component, factory trial assembly, on-site platform erection, longitudinal beam hoisting, positioning and welding, cross beam assembly, rack system installation and functional layer construction. The application has the advantages of simple structure, easy processing and transportation, convenient and fast on-site installation, improved driving safety and comfort, strong adaptability, obvious economic advantages, and is suitable for large and medium-sized city traffic branch lines and densified lines, and is especially suitable for complex line conditions.

Description

Technical Field

[0001] This invention relates to a prefabricated box-shaped steel track beam with a guide rail type rack system and its construction scheme, which is suitable for track with large longitudinal slopes (i≤250‰) and small horizontal curves (R≥30m), and belongs to the field of bridge engineering. Background Technology

[0002] With the gradual clarification of my country's urban rail transit development policies and the strengthening of the policy system's hierarchy, the trend towards diversified systems has become increasingly significant, providing favorable conditions for the diversified development of urban rail transit. The guide rail type rubber-tired system, as an important supplement to China's independent urban rail transit system, has broad application prospects, especially suitable for main lines in large and medium-sized cities, as well as branch lines and denser lines in megacities. This system, as a special type of tram, uses rubber wheels and combines running wheels with guide wheels located below and inside the wheels to achieve driving and steering functions on the guide rail beam. It mainly adopts an elevated laying method and can integrate driverless technology. Its one-way hourly capacity is 5,000 to 12,000 passengers, belonging to the low-capacity rail transit system, and has significant characteristics such as flexible formation, low energy consumption, low noise, simple operation and maintenance, lightweight design, diversified power supply methods, and independent right-of-way.

[0003] The guide rail type rubber-tired tram system, a type of tram using rubber wheels, is powered by energy storage devices. The vehicle travels and steers on the track beam through the cooperation of the running wheels and guide wheels. Train forward movement and braking are achieved through the friction between the rubber wheels and the track beam. However, due to the difference in friction coefficients between different materials, the magnitude of the friction is affected; therefore, the maximum gradient of the guide rail type rubber-tired system on the main line should not exceed 80‰. With increasing longitudinal gradient, especially under adverse weather conditions such as rain and snow, the risk of the rubber wheels slipping and spinning increases, thereby increasing the possibility of traffic accidents.

[0004] The guide rail rack system train achieves its movement by adding a drive gear to the bogie and meshing it with the rack, thus enhancing its climbing ability. It is suitable for lines with a maximum longitudinal gradient of 250‰, and is particularly well-suited to the high-altitude mountainous terrain of western my country. However, designing a track beam for the guide rail rack system train that is simple in structure, comfortable to ride, has low vibration and noise, and is easy to manufacture, transport, and install on-site remains a pressing technical challenge for engineers in this field. Summary of the Invention

[0005] The purpose of this invention is to provide a prefabricated box-shaped steel track beam for a guide rail type gear rail system and its construction method, so as to solve the problems of high processing difficulty, inconvenient transportation, and complex on-site installation of track beams in the prior art.

[0006] The technical solution adopted by the present invention to solve its technical problem is a guide rail type gear rail system assembled box-shaped steel rail beam, including two parallel longitudinal beams. The longitudinal beams include two oppositely arranged first beam plates. The tops of the two first beam plates are connected by a first top plate, and the bottoms of the two first beam plates are connected by a first bottom plate. Multiple crossbeams are arranged between the two longitudinal beams. The crossbeam includes two opposing second beam plates, the tops of which are connected by a second top plate, and the bottoms of which are connected by a second bottom plate. The crossbeam is connected to the longitudinal beam by a connecting beam, which is fixed to the inner wall of the longitudinal beam. The connecting beam has the same cross-section as the crossbeam. The top plate of the connecting beam is welded to the second top plate, and the bottom plate of the connecting beam is welded to the second bottom plate. The side plates of the connecting beam are connected to the second beam plates by splicing plate bolts. Each of the longitudinal beams is provided with a toothed rail structure located above the connecting beam on its inner side. The toothed rail structure includes a rack and a channel steel. The openings of the two channel steels are opposite each other, and the rack is set on the bottom wall of the channel steel. Friction blocks are provided on the two inner side walls of the channel steel. A damper is provided between the connecting beam and the toothed rail structure.

[0007] Furthermore, shock-absorbing pads are provided at the connection between the toothed rail structure and the longitudinal beam.

[0008] Furthermore, a support beam is provided between two adjacent crossbeams. The support beam is fixedly connected to the inner side of the longitudinal beam and located below the toothed rail structure. A damper is provided between the support beam and the toothed rail structure.

[0009] Furthermore, an anti-slip layer is provided on the top of the first top plate.

[0010] A construction method for an assembled box-girder steel track beam using a guide rail type rack and pinion system includes the following steps. S1. Factory prefabrication: Longitudinal beams are prefabricated in sections at the steel structure processing plant, with each section being 8-12m in length; crossbeams, connecting beams, and support beams are prefabricated simultaneously; the connecting beams and support beams are welded and fixed to the pre-set positions of the longitudinal beams; S2. In-factory trial assembly: The track beam is trial assembled as a whole before leaving the factory to verify the accuracy of the spatial curve and the interface matching. After passing the acceptance, it is transported to the construction site. S3. On-site platform construction: Construct an assembly platform at the bridge site; S4. Longitudinal beam hoisting and positioning: Use a truck crane or crawler crane to hoist the longitudinal beams in sections to the assembly platform and adjust them to the design elevation and plane position; S5. Welded connection of longitudinal beams: Weld the joints of adjacent longitudinal beam segments on site, and inspect the quality of the weld after the welding is completed; S6. Crossbeam assembly: Hoist the crossbeam to the designated position between the longitudinal beams, weld the top plate of the connecting beam to the second top plate, weld the bottom plate of the connecting beam to the second bottom plate, and connect the side plate of the connecting beam to the second beam plate by means of splicing plate bolts; S7. Gear rack system installation: Connect the gear rack structure to the inside of the longitudinal beam with bolts, and install dampers between the gear rack structure and the connecting beam and support beam; S8. Functional layer construction: Apply a 10mm thick layer of corundum mixed with a curing agent to the first top plate of the longitudinal beam to form an anti-slip layer.

[0011] The beneficial effects of this invention are: 1. Simple structure, easy to process and transport: The present invention adopts a prefabricated structure, which decomposes the track beam into multiple components for prefabrication and transportation, greatly reducing the processing difficulty and transportation cost.

[0012] 2. Convenient and quick on-site installation: By using factory prefabrication and on-site assembly, the construction cycle can be greatly shortened and construction efficiency improved.

[0013] 3. Improve driving safety and comfort: By installing devices such as shock absorbers, rubber shock absorber pads and graphite friction blocks, the vibration and noise of the train during operation can be effectively reduced, thereby improving ride comfort and driving safety.

[0014] 4. High adaptability: This invention is applicable to branch lines and dense lines in large and medium-sized cities. It has high torsional stiffness and anti-overturning ability and can adapt to various complex line conditions.

[0015] 5. Significant Economic Advantages: The track beam structure boasts significant self-weight advantages and compact component characteristics, with its single-span structural weight reduced by approximately 65% ​​compared to traditional concrete beams. While ensuring load-bearing capacity, it achieves material savings, reducing the construction cost per unit by 28% compared to prestressed concrete beams. This structural system exhibits outstanding low-carbon and environmentally friendly performance, with a life-cycle carbon emission intensity only 42% of that of concrete structures, and a steel recycling rate of up to 92%. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 yes Figure 1 Top view; Figure 3 yes Figure 2 Sectional view of AA; Figure 4 yes Figure 2 Sectional view of BB; Figure 5 This is a sectional view of the beam; Figure 6 This is a schematic diagram of the toothed rail structure.

[0017] Reference numerals: 1-Longitudinal beam; 101-First beam plate; 102-First top plate; 103-First bottom plate; 104-Anti-slip layer; 2-Crossbeam; 201-Second beam plate; 202-Second top plate; 203-Second bottom plate; 3-Connecting beam; 301-Splicing plate; 4-Rack and pinion structure; 401-Rack and pinion; 402-Channel steel; 403-Friction block; 404-Shock-absorbing pad; 5-Damper; 6-Supporting beam. Detailed Implementation

[0018] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0019] like Figures 1-5 As shown, the present invention provides a prefabricated box-shaped steel rail beam for a guide rail type gear rail system, comprising two parallel longitudinal beams 1, each longitudinal beam 1 comprising two opposing first beam plates 101, the tops of the two first beam plates 101 being connected by a first top plate 102, the bottoms of the two first beam plates 101 being connected by a first bottom plate 103, and multiple crossbeams 2 being provided between the two longitudinal beams 1. As the main load-bearing structure of the track beam, longitudinal beam 1 adopts a box-section design, possessing large bending and torsional moments of inertia, thus improving the overall stability and anti-overturning capacity of the track beam. The box-shaped longitudinal beam 1 consists of two parallel first beam plates 101, connected at the top by a first top plate 102 and at the bottom by a first bottom plate 103, forming a box structure. The first beam plates 101, first top plate 102, and first bottom plate 103 are connected by welding to ensure the integrity and stability of the structure. The width of the first top plate 102 and first bottom plate 103 is greater than the distance between the two first beam plates 101 to meet the load-bearing capacity and usage requirements of the track beam. The length of a single longitudinal beam 1 is 8-12m to facilitate transportation and on-site assembly. The box-section of longitudinal beam 1 results in larger bending and torsional moments of inertia compared to I-beams, leading to significantly smaller vertical and torsional deformations under the same vehicle load and swaying force. Taking a top and bottom slab with a beam height of 600mm, a thickness of 20mm, a width of 300mm, and a web thickness of 16mm as an example, the bending moment of inertia of the box section is 1.48 × 10⁻⁶. 9 mm 4 The torsional moment of inertia is 6.03 × 10⁻⁶. 8 mm 4 The bending moment of inertia of an I-shaped section of the same size is 1.24 × 10⁻⁶. 9 mm 4The torsional moment of inertia is 2.39 × 10⁻⁶. 6 mm 4 The bending moment of inertia and torsional moment of inertia of the box section are 1.2 and 252 times that of the I-section, respectively. The longitudinal beam 1 adopts a box section, which has a large torsional stiffness, especially under the condition of small curve radius of the line, which greatly improves its own anti-overturning ability.

[0020] The crossbeam 2 includes two opposing second beam plates 201. The tops of the two second beam plates 201 are connected by a second top plate 202, and the bottoms of the two second beam plates 201 are connected by a second bottom plate 203. The crossbeam 2 is connected to the longitudinal beam 1 by a connecting beam 3. The connecting beam 3 is fixed to the inner wall of the longitudinal beam 1. The connecting beam 3 has the same cross-section as the crossbeam 2. The top plate of the connecting beam 3 is welded to the second top plate 202, and the bottom plate of the connecting beam 3 is welded to the second bottom plate 203. The side plates of the connecting beam 3 are bolted to the second beam plates 201 by splicing plates 301. The crossbeam 2 is arranged perpendicular to the longitudinal beam 1, connecting adjacent longitudinal beams 1 and enhancing the overall rigidity of the track beam. The box-shaped crossbeam 2 consists of two opposing second beam plates 201, connected at the top by a second top plate 202 and at the bottom by a second bottom plate 203. The box-shaped crossbeam 2 is connected to the box-shaped longitudinal beam 1 by a connecting beam 3, which is fixed to the inner wall of the longitudinal beam 1 and has the same cross-section as the crossbeam 2. Since the splicing process is in an outdoor working environment, the top plate of the connecting beam 3 is welded to the second top plate 202, and the bottom plate is welded to the second bottom plate 203 to ensure the stability of the connection between the connecting beam 3 and the crossbeam 2. Simultaneously, the side plates are bolted to the second beam plates 201 via splicing plates 301, enabling rapid connection. The spacing between adjacent crossbeams 2 is 2m to meet the stress requirements of the track beam and ensure driving safety.

[0021] Each of the longitudinal beams 1 has a toothed rail structure 4 located above the connecting beam 3 on its inner side. The toothed rail structure 4 includes a rack 401 and a channel steel 402. The openings of the two channel steels 402 face each other. The rack 401 is set on the bottom wall of the channel steel 402. Friction blocks 403 are set on the two inner side walls of the channel steel 402. A damper 5 is set between the connecting beam 3 and the toothed rail structure 4.

[0022] The rack and pinion structure 4 can be connected to the longitudinal beam 1 by bolts or welding, but bolt connection is preferred for ease of replacement. The rack and pinion structure 4 is integrally cast from a rack 401 and a channel steel 402. The rack 401 meshes with the vehicle drive gear, enabling the train to move and climb. The upper and lower flanges of the channel steel 402 restrict the vertical displacement of the train gear, preventing the vehicle from overturning and derailing. The channel steel 402 is used to fix the rack 401, ensuring its accurate position and stability. Friction blocks 403 are installed on the two inner sidewalls of the channel steel 402 to prevent direct friction between the train drive gear and the channel steel 402 when the vehicle tends to overturn, ensuring the durability of the rack and pinion structure 4. A damper 5 is installed between the connecting beam 3 and the rack and pinion structure 4 to absorb and mitigate vibrations, protecting the track beam structure.

[0023] To reduce vibration between the gear mechanism and the longitudinal beam 1, a shock-absorbing pad 404 is further provided at the connection between the gear structure 4 and the longitudinal beam 1.

[0024] Since the interval between two adjacent crossbeams 2 is 2m, in order to better support the gear rack structure 4, a support beam 6 is further provided between the two adjacent crossbeams 2. The support beam 6 is fixedly connected to the inner side of the longitudinal beam 1 and located below the gear rack structure 4. A damper 5 is provided between the support beam 6 and the gear rack structure 4. The support beam 6 is I-shaped and is set below the longitudinal beam 1 to support and fix the gear rack structure 4.

[0025] Furthermore, an anti-slip layer 104 is provided on the top of the first top plate 102. A 10mm thick protective layer formed of corundum and curing agent is provided on the top of each longitudinal beam 1, i.e., the upper surface of the first top plate 102, to increase the adhesion between the track beam and the wheel. This can prevent the steel track beam from icing on the running surface in rainy or snowy weather, causing the wheel to slip, and can also reduce the vibration and noise generated by the steel track beam and the wheel.

[0026] A construction method for an assembled box-girder steel track beam using a guide rail type rack and pinion system includes the following steps. S1. Factory prefabrication: The longitudinal beam 1 is prefabricated in sections at the steel structure processing plant, with a single section length of 8-12m; the cross beam 2, connecting beam 3 and supporting beam 6 are prefabricated simultaneously; the connecting beam 3 and supporting beam 6 are welded and fixed to the preset positions of the longitudinal beam 1. S2. In-factory trial assembly: The track beam is trial assembled as a whole before leaving the factory to verify the accuracy of the spatial curve and the interface matching. After passing the acceptance, it is transported to the construction site. S3. On-site platform construction: Construct an assembly platform at the bridge site; for example, if the pier spacing is 30m and the longitudinal beam length is 8-12m, an assembly platform needs to be constructed at the bridge site between the two piers to splice the two longitudinal beams.

[0027] S4. Longitudinal beam hoisting and positioning: Use a truck crane or crawler crane to hoist the longitudinal beam 1 section to the assembly platform and adjust it to the design elevation and plane position; S5. Welded connection of longitudinal beams: Weld the joints of adjacent longitudinal beams in the field, and inspect the quality of the weld after the welding is completed; S6. Horizontal beam assembly: hoist the horizontal beam 2 to the designated position between the longitudinal beam 1, weld the top plate of the connecting beam 3 to the second top plate 202, weld the bottom plate of the connecting beam 3 to the second bottom plate 203, and bolt the side plate of the connecting beam 3 to the second beam plate 201 through the splicing plate 301. S7. Installation of the rack and pinion system: Connect the rack and pinion structure 4 to the inside of the longitudinal beam 1 with bolts, and install the damper 5 between the rack and pinion structure 4 and the connecting beam 3 and the support beam 6; S8. Functional layer construction: A 10mm thick layer of corundum mixed with a curing agent is applied to the first top plate 102 of the longitudinal beam 1 to form an anti-slip layer 104.

[0028] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A prefabricated box-shaped steel rail beam for a guide rail type rack and toothed rail system, comprising two parallel longitudinal beams (1), characterized in that: The longitudinal beam (1) includes two first beam plates (101) arranged opposite to each other. The tops of the two first beam plates (101) are connected by a first top plate (102), and the bottoms of the two first beam plates (101) are connected by a first bottom plate (103). Multiple crossbeams (2) are provided between the two longitudinal beams (1). The crossbeam (2) includes two opposing second beam plates (201), the tops of the two second beam plates (201) are connected by a second top plate (202), and the bottoms of the two second beam plates (201) are connected by a second bottom plate (203); the crossbeam (2) is connected to the longitudinal beam (1) by a connecting beam (3), the connecting beam (3) is fixed on the inner side wall of the longitudinal beam (1), the connecting beam (3) has the same cross-section as the crossbeam (2), the top plate of the connecting beam (3) is welded to the second top plate (202), the bottom plate of the connecting beam (3) is welded to the second bottom plate (203), and the side plate of the connecting beam (3) is bolted to the second beam plate (201) by a splicing plate (301); Each of the longitudinal beams (1) has a toothed rail structure (4) located above the connecting beam (3) on its inner side. The toothed rail structure (4) includes a rack (401) and a channel steel (402). The openings of the two channel steels (402) are opposite to each other. The rack (401) is set on the bottom wall of the channel steel (402). Friction blocks (403) are set on the two inner side walls of the channel steel (402). A damper (5) is set between the connecting beam (3) and the toothed rail structure (4).

2. The prefabricated box girder beam of the guide rail type geared rail system as described in claim 1, characterized in that: A shock-absorbing pad (404) is provided at the connection between the toothed rail structure (4) and the longitudinal beam (1).

3. The prefabricated box-shaped steel track beam of the guide rail type rack system as described in claim 1, characterized in that: A support beam (6) is provided between two adjacent crossbeams (2). The support beam (6) is fixedly connected to the inner side of the longitudinal beam (1) and located below the toothed rail structure (4). A damper (5) is provided between the support beam (6) and the toothed rail structure (4).

4. The prefabricated box girder beam of the guide rail type rack and toothed rail system as described in claim 1, characterized in that: The top of the first top plate (102) is provided with an anti-slip layer (104).

5. A construction method for an assembled box-girder steel track beam using a guide rail type rack and pinion system, characterized in that: The assembled box girder beam using a guide rail type rack and pinion system as described in any one of claims 1-4 includes the following steps: S1. Factory prefabrication: The longitudinal beams (1) are prefabricated in sections at the steel structure processing plant, with a single section length of 8-12m; the cross beams (2), connecting beams (3) and supporting beams (6) are prefabricated simultaneously; the connecting beams (3) and supporting beams (6) are welded and fixed to the preset positions of the longitudinal beams (1); S2. In-factory trial assembly: The track beam is trial assembled as a whole before leaving the factory to verify the accuracy of the spatial curve and the interface matching. After passing the acceptance, it is transported to the construction site. S3. On-site platform construction: Construct an assembly platform at the bridge site; S4. Longitudinal beam hoisting and positioning: Use a truck crane or crawler crane to hoist the longitudinal beam (1) in sections to the assembly platform and adjust it to the design elevation and plane position; S5. Welding connection of longitudinal beams: Weld the joints of adjacent longitudinal beams (1) on site, and conduct weld quality acceptance after the welding is completed; S6. Horizontal beam assembly: hoist the horizontal beam (2) to the designated position between the longitudinal beam (1), weld the top plate of the connecting beam (3) to the second top plate (202), weld the bottom plate of the connecting beam (3) to the second bottom plate (203), and connect the side plate of the connecting beam (3) to the second beam plate (201) by bolting the splicing plate (301); S7. Installation of the rack system: Connect the rack structure (4) to the inside of the longitudinal beam (1) by bolts, and install a damper (5) between the rack structure (4) and the connecting beam (3) and the support beam (6); S8. Functional layer construction: A 10mm thick layer of corundum mixed with curing agent is applied to the first top plate (102) of the longitudinal beam (1) to form an anti-slip layer (104).

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