Special equipment for group replacement of high-speed railway turnouts and construction method

Abstract

The invention provides special equipment for group replacement of high-speed railway turnouts and a construction method, and belongs to the technical field of railway engineering. Comprising a heavy rail car, a container type rail welding car, a plurality of special turnout transportation flatcars, a container type rail welding car and a heavy rail car which form a whole-column special marshalling used for integrated operation of transportation, replacement, welding and recovery of grouped rail pieces. A rail welding vehicle folding arm crane, a flash welding machine, rail welding vehicle auxiliary supporting legs and the like are carried on the container type rail welding vehicle; at least two flatcar folding arm cranes, flatcar auxiliary supporting legs, a lifting handrail and a special loading tool are installed on the special turnout transportation flatcar. Special equipment and a construction method are used for achieving integrated operation of the high-speed railway turnout from bulk material pre-assembly to group transportation, replacement, welding and old turnout recycling, the problem that group replacement of an existing high-speed railway turnout is completed at a skylight point is solved, and the defects of a group replacement operation technology of the high-speed railway turnout are overcome.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of railway engineering, and particularly relates to a special equipment for group replacement of high-speed railway turnout and a construction method. BACKGROUND

[0002] With the increase of the operation time of high-speed railways in China, the continuously segmented diseases of the existing service ballastless turnouts are caused by the multiple factors of complex operation conditions and climate environment. Therefore, the demand for the replacement technology of high-speed railway ballastless turnouts is increasingly urgent. However, the existing high-speed railway ballastless turnouts are mainly transported to the nearby transit field near the construction site in the form of single pieces of switch rail assembly (with a pad), frog assembly (with a pad), guide curve and guard rail, and then are transported to the construction site by rail car through the skylight point for block assembly replacement. This replacement method of ballastless turnouts not only has a low degree of mechanical automation, but also needs a large number of construction personnel and numerous small machines during the on-site replacement process. This construction operation method not only consumes time and effort, but also is limited by the on-site operation environment, so that the assembly precision of the turnout is lower than the precision of the pre-assembly in the turnout factory, which is not conducive to the long-term application of the new replaced turnout.

[0003] Therefore, it is necessary to provide a turnout replacement method and a matching group track piece transportation and replacement equipment for high-speed railway turnouts, which have a higher degree of intelligentization and automation and integrate the operations of pre-paving, transportation, replacement, welding and old turnout recycling, so as to solve the problems of time-consuming and low assembly precision in the existing construction operation project, so as to realize the operation goal of material netting after work and field cleaning after people. SUMMARY

[0004] The technical problem solved by the present application is to overcome the shortcomings of the prior art and provide a special equipment for group transportation and replacement of high-speed railway turnouts and a construction method, so as to realize efficient, high-precision and integrated turnout replacement operation.

[0005] To achieve the above-mentioned purpose, the technical solution adopted by the present application is as follows: The special equipment for group replacement of high-speed railway turnouts comprises a traction power unit, a welding operation unit and a turnout transportation unit. The traction power unit comprises two heavy rail cars, which are respectively coupled at the two ends of the whole train. The welding operation unit comprises two container-type welding cars, which are respectively coupled at the inner sides of the traction power unit. Each container-type welding car is loaded with a welding car folding crane, a flash butt welding machine and a welding car auxiliary leg, a generator container and a welding machine crane power device. The welding car folding crane is used to move the flash butt welding machine to the adjacent line rail joint for welding operation. The turnout transport unit comprises several special turnout transport flat cars arranged between the first and last welding operation units; at least two flat car folding arm cranes, flat car auxiliary legs, and special loading tooling, and flat car crane power devices are installed on each special turnout transport flat car; the flat car folding arm crane is used for lifting operation of the turnout group track pieces, and the special loading tooling is used for layered loading and fixing of the pre-paved turnout group track pieces. The heavy rail car, the container type rail welding car, and the special turnout transport flat car are connected through car couplings to form an integrated operation consist.

[0006] Further to the above-mentioned scheme, a large slewing bearing is additionally arranged at the lower part of the slewing device of the flat car folding arm crane on the special turnout transport flat car, and the base of the flat car folding arm crane can be transversely changed in position relative to the car frame through the large slewing bearing, so that the operation range of the flat car folding arm crane covers the left or right adjacent line of the line; a slewing reducer 322 is arranged on the large slewing bearing 321 to realize slewing drive of the crane itself.

[0007] Further to the above-mentioned scheme, the large slewing bearing can be replaced by a set of transverse guide rail mechanism, and the transverse movement and positioning of the base of the flat car folding arm crane are realized through the transverse guide rail mechanism.

[0008] Further to the above-mentioned scheme, the special loading tooling comprises at least two layers of bearing structures: a first layer of rotary transverse support platform for loading the turnout core segment group track pieces; and a second layer of rotary transverse support platform for loading the straight switch rail segment and curved lower strand group track pieces; the rotary transverse support platform can make the group track pieces loaded thereon produce necessary transverse movement and rotation in the transportation process to adapt to the curved line and pass through.

[0009] In furtherance of the above-mentioned solution, the structure of the special loading tool comprises a tool rotary bearing seat and a tool support, which are matched with the floor of the frame and can rotate around the rotary bearing seat on the floor of the frame to adjust the position of the tool on the frame, so as to meet the rail loading under different working conditions; a universal ball is installed at the lower part of the tool support, which can roll during the rotation of the tool while meeting the bearing condition, so as to reduce the rotation resistance; a first layer of slide way frame and a second layer of slide way frame are sequentially arranged from bottom to top on the upper part of the tool rotary bearing seat and the tool support, the lower part of the first layer of slide way frame is fixedly connected with the tool rotary bearing seat and the tool support, a first layer of rotary horizontal moving support is arranged on the first layer of slide way frame, the slide plates on both sides of the first layer of rotary horizontal moving support are slidably matched with the slide grooves on the first layer of slide way frame; a long supporting positioning pin and a short supporting positioning seat are respectively arranged at the two ends of the first layer of slide way frame, one end of the second layer of slide way frame is rotatably inserted into the long supporting positioning pin through a pin hole, the other end of the second layer of slide way frame is matched with the single-side stop edge of the short supporting positioning seat, so as to facilitate the rotation and moving away of the second layer of slide way frame around the long supporting positioning pin in a specified direction; a driving oil cylinder is installed between the long supporting positioning pin and the second layer of slide way frame, the second layer of slide way frame and the second layer of rotary horizontal moving support thereon can be driven to rotate and fix an angle, so as to facilitate the hoisting of the rail on the first layer of rotary horizontal moving support; a second layer of rotary horizontal moving support is arranged on the second layer of slide way frame, the slide plates on both sides of the second layer of rotary horizontal moving support are slidably matched with the slide grooves on the second layer of slide way frame; the first layer of rotary horizontal moving support and the second layer of rotary horizontal moving support are both provided with locking devices.

[0010] In furtherance of the above-mentioned solution, the plurality of folding arm cranes on the special turnout transport flat car are equipped with a synchronous control system; the synchronous control system comprises a displacement sensor, a tension sensor and an angle encoder; the displacement sensor is used to collect the displacement data of each lifting point and perform closed-loop control with displacement synchronization as the target; the tension sensor is installed at the lifting point and is used to monitor the lifting force in real time and feed back to the main control system for tension synchronization protection; the angle encoder is used to feed back the rotation angle of each folding arm crane in real time, so as to realize rotary synchronous control.

[0011] In furtherance of the above-mentioned solution, the folding arm crane of the welding rail car on the container type welding rail car is also equipped with the synchronous control system and can realize the welding of adjacent rail joints within a range of 5.5m of the farthest line spacing; the flat car folding arm crane on the special turnout transport flat car can realize the lifting of adjacent lines within a range of 5.5m of the farthest line spacing.

[0012] Further limitation to the above scheme, the special turnout transport flat car is equipped with an automatically liftable barrier, which is lifted to form a safety protection during daily parking and rail piece transportation, and is lowered to not affect the lifting operation of the assembled rail pieces during the lifting operation of the rail pieces.

[0013] A high-speed railway turnout replacement construction method, which applies the special equipment, comprises the following steps: S1. Transporting the rail pieces in bulk to a rail piece pre-paving base; S2. Grouping the train according to the length of the extension rail of the turnout to be replaced on the parking line of the pre-paving base, and assembling and pre-paving the rail pieces in bulk on the ground beside the parking line; S3. Loading the assembled rail pieces on the special turnout transport flat car, loading the frog section on the first layer and loading the straight rail section and the curved lower stock on the second layer, and using the special loading tool on the flat car to constrain and fix; S4. After the opening of the sky window, the train is grouped and runs to the construction site, and the preparation work of cutting the old rail and removing the ground anchor is simultaneously performed; S5. Positioning the train at the site, lowering the auxiliary legs on the turnout transport flat car, and preparing for the operation; S6. Using the flat car folding arm crane to hoist and place the cut old turnout sections in sequence to the temporary storage between the two lines; S7. Resetting the flat car folding arm crane and unlocking the second layer of the special loading tool; S8. Hoisting the straight rail section and the curved lower stock of the new turnout to the designated position and performing fine adjustment and positioning; S9. Resetting the flat car folding arm crane, unlocking the first layer of the special loading tool, hoisting the frog section to the designated position, and then retracting the auxiliary legs of the turnout transport flat car; S10. Restoring the electrical equipment; S11. Small displacement of the train group to position the container type rail welding car, and lowering the auxiliary legs of the welding car; S12. Two container type rail welding cars simultaneously perform flash welding and heat treatment on the joints before and after the turnout; and perform connection operations such as joint grinding, flaw detection and curved stock clamping plate installation; S13. The container type rail welding car retracts the hoisting arm and the leg in sequence, and locks the train group; S14. Measuring the gauge, direction and level parameters of the turnout and performing fine adjustment; S15. Lowering the auxiliary legs of the turnout transport flat car, and loading and fixing the old turnout sections on the special turnout transport flat car in sequence; S16. After on-site inspection and confirmation, the train group returns to the pre-paving base, and the replacement operation is completed.

[0014] Further limitation to the above scheme, the base pre-paving method in step S2 comprises: S21. placing the track piece pre-paving special tool on the site beside the pre-paving base stop line; S22. accurately adjusting the positions of the various pads on the pre-paving special tool workbench according to the bolt hole position data of the to-be-replaced turnout section obtained through site investigation and mapping; S23. performing start-up preparation for each special turnout transport flat car in the train consist, and lowering the flat car auxiliary legs carried along; S24. using the flat car folding arm crane on the special turnout transport flat car to hoist the track piece bulk material to the workbench of the pre-paving special tool; S25. adjusting the positions of the track piece pads according to the hole distance of the pads on the workbench, and completing the assembly alignment of the turnout track piece bulk material; S26. performing welding on the assembly-aligned track piece bulk material to form the three-section assembled track piece of the straight frog section, the frog section and the curved lower stock section according to the section based on the glued joint; S27. performing flaw detection and standing treatment on the three-section assembled track piece after welding.

[0015] Further limitation of the above scheme, the loading method of the assembled track piece in the base in the above step S3 comprises: S31. parking the train consist on the base stop line, performing start-up preparation for each special turnout transport flat car, lowering the flat car auxiliary legs, and adjusting the large rotation support of the flat car folding arm crane and the load tool rotation support to a suitable hoisting position; S32. opening the special loading tool on each special turnout transport flat car, using the flat car folding arm crane to multi-point hoist the frog section assembled track piece, hoisting it to the rotating transfer platform of the first layer of the special loading tool, and adjusting its position to make it as close to the longitudinal center line of the flat car as possible; S33. locking the lock of the first layer of the special loading tool; S34. using the flat car folding arm crane to multi-point hoist the curved lower stock section assembled track piece, and hoisting it to the rotating horizontal transfer platform of the second layer of the special loading tool; S35. using the flat car folding arm crane to multi-point hoist the straight frog section assembled track piece, hoisting it to the rotating horizontal transfer platform of the second layer of the special loading tool, and adjusting its position to make its center of gravity as close to the longitudinal center line of the flat car as possible; S36. sequentially retracting each flat car folding arm crane and flat car auxiliary leg to the transport position; S37. locking the lock of the second layer of the special loading tool, and completing the loading.

[0016] Compared with the prior art, the present application has the following advantages: 1. The scheme integrates efficient operation: using special equipment and construction methods can realize the integrated operation of high-speed railway turnout from bulk pre-assembly to group transportation, replacement, welding and old turnout recovery, complete the replacement of the whole turnout in one window point, greatly improve the operation efficiency, and realize "work finished material clean, people clear"; 2. The scheme has high precision and high quality: by pre-paving in the base to ensure assembly accuracy, reduce the number of on-site operation links and welding joints, and through special tooling and synchronous control system to ensure the state of the rail during transportation and hoisting, significantly improve the installation quality and service life of the new replacement turnout; 3. The scheme is highly mechanized and intelligent: the equipment integrates multiple functions, uses intelligent technologies such as synchronous control and sensor monitoring, greatly reduces labor input, reduces labor intensity, improves operation safety and reliability; 4. The scheme has good adaptability: special equipment can be flexibly grouped to meet the transportation needs of different length extension rails; the crane can be designed with large rotary support or transverse guide rail to adapt to the operation needs of different adjacent lines on the left and right, and the special loading tooling can ensure the safe passage of the vehicle through the small radius curve; 5. The scheme is economical and environmentally friendly: it reduces the dependence on multiple small machines and a large number of manpower, reduces the comprehensive construction cost, reduces the on-site operation time and traffic interference, and is more economical and environmentally friendly. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 is the main view of the grouping structure of the special equipment in the transportation state of the present application; Figure 2 is the top view of the grouping structure of the special equipment in the transportation state of the present application; Figure 3 is a structural schematic view of the container type welding rail car in the present application; Figure 4 is a structural schematic view of the special turnout transportation flat car in the present application; Figure 5 is a schematic view of the crane of the special turnout transportation flat car located at different operation sides ((a) right side (b) left side); Figure 6 is the main view of the special loading tooling of the present application; Figure 7 is the structural isometric view of the special loading tooling of the present application; Figure 8 is a structural schematic view of the rotating transverse bearing platform in the special loading tooling of the present application; Figure 9 is a schematic view of the straight nose rail in the grouping of turnout rails of the present application; Figure 10 is a schematic view of the frog section in the grouping of turnout rails of the present application; Figure 11 is a schematic view of a lower switch rail of the switch rail grouping of the present application; Figure 12 is a schematic flow chart of the construction method of the present application. DETAILED DESCRIPTION

[0018] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0019] It should be noted that, in this document, the terms "comprising", "containing", or any other variant thereof are intended to cover non-exclusive inclusions, so that a process, method, article, or device that includes a series of elements not only includes those elements, but also includes other elements not explicitly listed, or includes elements inherent to such a process, method, article, or device. Without more limitations, the element defined by the phrase "comprising a" does not exclude the presence of additional identical elements in the process, method, article, or device that includes the element.

[0020] Please refer to Figures 1-12 for detailed description of the embodiments of the present application.

[0021] Please refer to Figures 1 to 2 , the special equipment for high-speed railway switch grouping replacement mainly consists of a traction power unit, a welding operation unit, and a switch transportation unit.

[0022] The traction power unit includes two heavy rail cars 1, which are respectively grouped at the two ends of the entire train.

[0023] The welding operation unit includes two container-type rail welding cars 2, which are respectively grouped at the inner sides of the traction power unit. As shown in Figure 3 , each container-type rail welding car 2 is loaded with a rail welding car knuckle boom crane 23, a flash butt welding machine 24, a rail welding car auxiliary support leg 22, a generator container 21, and a welding machine crane power device 25; the rotation and extension of the rail welding car knuckle boom crane 23 can move the flash butt welding machine 24 to the adjacent rail joint for welding operation. Before the welding operation, the rail welding car auxiliary support leg 22 is first lowered, and then the welding operation is performed, so as to ensure the safety of the entire train during the welding operation.

[0024] In this embodiment, one container-type rail welding car is arranged at each end of the special train, which can simultaneously weld the rail joints before and after the switch after replacement, so as to improve the operation efficiency.

[0025] The turnout transport unit comprises several special turnout transport flat cars 3 arranged between the first and last welding operation units. Referring to Figures 4 to 5 At least two flat car folding arm cranes 32, flat car auxiliary legs 33 and special loading tooling 31, flat car crane power devices 34 are installed on each special turnout transport flat car 3. The flat car folding arm crane 32 is used for lifting the turnout group rail pieces, and the auxiliary legs are matched during lifting to ensure the safety and reliability of the lifting operation. The special loading tooling 31 is used for layer-by-layer loading and fixing the completed pre-paved turnout group rail pieces, and realizing the necessary rotation and transverse movement when passing through the curve to adapt to the deformation caused by the curve line, to ensure the loading reliability during transportation and the coordinated deformation of the group rail pieces when the train passes through the curve, to improve the stress state during transportation.

[0026] The above-mentioned heavy rail car 1, container type rail welding car 2 and special turnout transport flat car 3 are coupled in a specific order to form a special train set integrating the functions of transportation, replacement, welding and recycling.

[0027] Preferably, in addition to the slewing device of the flat car folding arm crane 32 on the special turnout transport flat car 3, a large slewing bearing 321 is additionally arranged at the lower part of the flat car folding arm crane 32, and through the large slewing bearing 321, the base of the flat car folding arm crane 32 can be transversely shifted relative to the car frame, so that the operation range of the flat car folding arm crane 32 covers the left adjacent line or the right adjacent line of the line. A slewing reducer 322 is arranged on the large slewing bearing 321 to realize the slewing drive of the crane itself Preferably, the large slewing bearing 321 can be replaced by a transverse movement guide rail mechanism, and the transverse movement and positioning of the base of the flat car folding arm crane 32 are realized through the transverse movement guide rail mechanism, so as to realize the operation requirements of lifting the left adjacent line or the right adjacent line of different lines.

[0028] In order to realize the assembly and welding operation of the turnout scattered parts after being transported to the pre-paving base, a special loading tooling is designed to provide a reliable and stable assembly foundation for the scattered turnout assembly. The special loading tooling serves as a pre-assembly workbench, and the positions of the various pads on the workbench can be accurately adjusted through adjusting the corresponding adjusting screws, so as to match the positions of the bolt holes obtained through on-site investigation and surveying. Specifically, referring to Figure 6As shown, the special loading fixture 31 includes at least two layers of load-bearing structure: the first layer, a rotating transverse support platform 312, is used to load the turnout section 5 of rail components; the second layer, a rotating transverse support platform 313, is used to load the straight tip section 4 and the curved lower section 6 of rail components. The rotating transverse support platforms 312 and 313 enable the rail components loaded on them to undergo necessary lateral movement and rotation during transportation to adapt to curved tracks. Simultaneously, each special loading fixture is equipped with a slewing bearing at its lower part, which can be used in conjunction with the crane's large slewing bearing for rotational positioning, thereby maximizing the use of loading space while facilitating the lifting of the rail components after the crane has rotated.

[0029] See Figures 6 to 7 The structure of the special loading fixture 31 includes a slewing bearing seat 311 and a fixture support 314. The slewing bearing seat 311 and the fixture support 314 mate with the chassis floor surface, allowing rotation around the slewing bearing seat on the chassis floor surface to adjust its position on the chassis, thus meeting the requirements for rail component loading under different working conditions. A universal ball joint is installed at the lower part of the fixture support 314, which can achieve rolling during fixture rotation while meeting load-bearing requirements, thereby reducing rotational stress. Resistance; the upper part of the tooling slewing bearing 311 and tooling support 314 is provided with a first layer of slide rail 319 and a second layer of slide rail 320 from bottom to top. The lower part of the first layer of slide rail 319 is fixedly connected to the tooling slewing bearing 311 and tooling support 314. The first layer of slide rail 319 is provided with a first layer of rotating transverse support platform 312. The sliding plates on both sides of the first layer of rotating transverse support platform 312 are slidably adapted to the sliding grooves on the first layer of slide rail 319; the first layer of slide rail At both ends of 319 are respectively provided a long support positioning pin 316 and a short support positioning seat 317. One end of the second-layer slide rail 320 is rotatably inserted into the long support positioning pin 316 through a pin hole, and the other end of the second-layer slide rail 320 is adapted to the single-sided stop of the short support positioning seat 317, so that the second-layer slide rail 320 can rotate and move away around the long support positioning pin 316 in a specified direction. A drive cylinder 315 is installed between the long support positioning pin 316 and the second-layer slide rail 320, and drives the cylinder to move away by the drive cylinder. The cylinder can drive the second-layer slide frame 320 and the second-layer rotating transverse support platform 313 thereon to rotate at a fixed angle, thereby facilitating the hoisting of rail components onto the first-layer rotating transverse support platform 312. The second-layer slide frame 320 is equipped with the second-layer rotating transverse support platform 313, and the sliding plates on both sides of the second-layer rotating transverse support platform 313 are slidably fitted into the sliding grooves on the second-layer slide frame 320. Both the first-layer rotating transverse support platform 312 and the second-layer rotating transverse support platform 313 are equipped with locking devices 318. The locking devices 318 are used to press the iron pads on both sides of the ends of the turnout rail components, thus fixing the turnout rail components. (See also...) Figure 8As shown, each locking device 318 includes two pressure plates. One end of the two pressure plates engages with the locking plate on the side of the rotating transverse support via a locking rod. After the two pressure plates press down the corresponding pads, their other ends are tightened and fixed by bolts.

[0030] The lateral and rotation devices attached to the aforementioned special loading fixture can ensure that the stress and deformation of the rail components are within the linear elastic range when the train is transporting turnout rail components through a minimum R180 curve. This ensures reliable loading and transportation without causing plastic deformation or stress exceeding the limit damage to the rail components.

[0031] In addition, the multiple folding boom cranes 32 on the dedicated turnout transport flatcar 3 are equipped with a control system that prioritizes displacement synchronization and protects against tension synchronization. The synchronization control system includes displacement sensors, tension sensors, and angle encoders. The displacement sensors are used to collect displacement data at each lifting point and perform closed-loop control with displacement synchronization as the goal. The tension sensors are installed at the lifting points to monitor the lifting force in real time and feed it back to the main control system for tension synchronization protection. The angle encoders are used to provide real-time feedback on the rotation angle of each folding boom crane 32, thereby achieving synchronous rotation control of different folding boom cranes during lifting operations.

[0032] The rail welding vehicle folding boom crane 23 on the containerized rail welding vehicle 2 is also equipped with the aforementioned synchronous control system and can perform rail joint welding operations on adjacent lines within a maximum line spacing of 5.5m; correspondingly, the flatcar folding boom crane 32 on the dedicated turnout transport flatcar 3 can perform lifting operations on adjacent lines within a maximum line spacing of 5.5m.

[0033] The dedicated turnout transport flatcar 3 is equipped with an automatically lifting guardrail. During normal parking and rail component transportation, the lifting guardrail is raised to provide safety protection. When rail components are being lifted, the lifting guardrail is lowered so as not to affect the lifting operation of groups of rail components.

[0034] A method for replacing high-speed railway turnouts in groups is disclosed, utilizing the aforementioned specialized equipment. In this embodiment, the specialized equipment is assembled as follows: 1 GCD-1000 heavy-duty railcar + 2 containerized rail welding cars + several dedicated turnout transport flatcars 3 + 2 containerized rail welding cars + 1 GCD-1000 heavy-duty railcar, forming a dedicated trainset for integrated transportation, replacement, welding, and recycling of grouped rail components. Two GCD-1000 heavy-duty railcars serve as traction power, and two containerized rail welding cars are used for welding adjacent rail joints at the turnout replacement site. Furthermore, the specialized equipment includes several 25m long dedicated turnout transport flatcars; taking an example with 25m extension rails before and after the turnout, the required number of flatcars is determined based on the total length.

[0035] For detailed construction methods, please refer to [link / reference]. Figure 12 As shown, it includes the following steps: S1. Loose rail components are transported to the rail component pre-laying base by road or a combination of road and rail (after conducting on-site research on the current status of existing major high-speed rail infrastructure maintenance bases, it was determined that the high-speed rail infrastructure maintenance work area would be used as the base for the pre-laying of loose rail components, so as to quickly transfer the pre-laid grouped rail components to the construction site).

[0036] S2. Based on the length of the extended rails to be replaced, trains are assembled on the stopping line of the pre-laying base, and loose rail components are pre-laid. Considering the case of 25m extended rails before and after the turnout, the original loose rail components are pre-laid and welded at the base to form three groups of rail components: straight switch rail 4, turnout center section 5, and curved lower rail 6. (See reference...) Figures 9-11 As shown.

[0037] In this step, when the rail components are pre-laid at the pre-laying base, a tracked flash welding machine for both road and rail is also provided to realize the welding of loose rail components at the pre-laying base, thereby forming the prescribed grouped rail component sections. In addition, the tracked flash welding machine not only has strong site adaptability and high operating efficiency, but its turnout flash welding machine head can also perform welding operations on the rail components in the turnout area.

[0038] The base pre-laying method in step S2 above includes the following steps: S21. Place the special tooling for pre-laying rail components on the ground next to the pre-laying base stop line; S22. Based on the bolt hole location data of the turnout section to be replaced obtained from the on-site survey and mapping, accurately adjust the position of each pad on the pre-laid special tooling workbench; S23. Each dedicated turnout transport flatcar 3 in the train set is prepared for startup, and the accompanying flatcar auxiliary support legs 33 are lowered. S24. Use the flatcar folding boom crane 32 on the dedicated turnout transport flatcar 3 to lift the loose rail components onto the workbench of the pre-laid special tooling; S25. Adjust the position of the rail component pad according to the hole spacing of the pad on the workbench to complete the assembly and alignment of the turnout rail component bulk materials; S26. Based on the adhesive joint, a dual-purpose track flash welding machine for both road and rail uses a flash welding machine to weld the assembled and aligned rail components to form three groups of rail components: straight tip rail section 4, turnout section 5, and curved lower rail 6. S27. Perform flaw detection and static treatment on the three-section rail assembly after welding.

[0039] S3. The assembled and pre-laid rail components are loaded onto the dedicated turnout transport flatcar 3. The turnout center section 5 is installed on the first-layer rotating transverse support platform 312, and the straight tip rail section 4 and the curved lower rail 6 are installed on the second-layer rotating transverse support platform 313. The rail components are then secured using the locking device on the dedicated loading fixture 31. After the rail components are loaded at the pre-laying base, the train waits for the closure signal and track maintenance window information for the line where the turnout to be replaced is located.

[0040] In step S3 above, the method for loading the group of rail components at the base includes the following steps: S31. The train sets are parked in place on the base parking line. Each dedicated turnout transport flatcar 3 is prepared for startup. The flatcar auxiliary outriggers 33 are lowered, and the large slewing bearing 321 of the flatcar folding boom crane 32 and the load-bearing fixtures are adjusted to rotate to the appropriate lifting position. S32. Open the special loading fixture 31 on each special turnout transport flatcar 3, use the flatcar folding boom crane 32 to lift the turnout section 5 rail components at multiple points, place them on the rotating transfer bearing platform 312 on the first layer of the special loading fixture 31, and adjust their position so that they are as close as possible to the longitudinal centerline of the flatcar. S33. Lock the first layer of the special loading fixture 31; S34. Use the flatcar folding boom crane 32 to lift the six groups of rail components of the lower curved section at multiple points and place them on the second-layer rotating transverse bearing platform 313 of the special loading fixture 31. S35. Use the flatcar folding boom crane 32 to lift the four groups of straight and pointed rail sections at multiple points, place them on the second layer of rotating transverse support platform 313 of the special loading fixture 31, and adjust their position so that their center of gravity is as close as possible to the longitudinal center line of the flatcar. S36. Retract the flatcar folding boom crane 32 and the flatcar auxiliary outriggers 33 to the transport position in sequence; S37. Lock the second layer of the special loading fixture 31 to complete the loading.

[0041] S4. After the track maintenance window opens, the assembled rail components that have been loaded and reinforced will be transported to the construction site where the turnout needs to be replaced using the aforementioned train formations. To improve the utilization rate of the track maintenance window, after the window opens, the workers at the construction site will simultaneously carry out a series of preparatory work, such as cutting the old rails, removing the ground anchors, disconnecting the power grid, and dismantling the electrical system.

[0042] S5. After the train convoy arrives at the construction site, the convoy is moved and aligned according to the location of the turnouts to be replaced, ensuring that all lifting and welding points are within the working range of the corresponding crane booms after the convoy is parked. Then, the train is stopped to prepare for startup and the outriggers on the special flatcars for transporting each turnout are lowered.

[0043] S6. After the outriggers are lowered and preparations are completed, the folding boom cranes on the special flatcar for transporting turnout rail components are started, rotated, and extended to the position of the old turnout to be replaced on the adjacent line. The old turnout, which has been cut into sections, is lifted and placed between the two lines. During lifting, the loading for subsequent old turnout recovery must be considered; therefore, the lifting should proceed in the order of straight tip rail section, curved lower rail, and turnout center section. Furthermore, to ensure the safety and reliability of the on-site lifting operation, a small pre-lift should be performed as early as possible. After confirming that the lifting equipment is normal, normal lifting operations can then proceed.

[0044] S7. After completing the hoisting of each section of the old turnout to the two lines, reset each folding boom crane, and then unlock the second layer of the tooling loaded on the special flatcar.

[0045] S8. Each folding boom crane sequentially lifts the straight-point rail section and the curved-strip rail assembly loaded on the second layer of the tooling from multiple points and places them at the designated position of the turnout to be replaced. Similarly, a small pre-lift is performed before lifting to confirm that the lifting equipment is normal before proceeding with the normal lifting operation. Before lowering, fine-tuning and alignment are also performed to ensure the accuracy of the new turnout's placement.

[0046] S9. Retract and reset the folding boom crane, unlock the first layer of the tooling on the special flatcar, and then lift the group of rail components of the turnout section to the designated position of the turnout to be replaced.

[0047] S10. After all three sections of the rail assembly are hoisted to the designated position of the turnout to be replaced, the previously removed electrical components are reinstalled, and the folding boom cranes and auxiliary outriggers of each flatcar are simultaneously retrieved, and the loading fixtures that were previously unlocked are locked.

[0048] S11. The parking train set is slightly shifted along its track to allow the containerized rail welding cranes at both ends of the train set to extend their welding machines to the welding joint. After the shift is complete, the rail welding crane is prepared to start up, and the auxiliary outriggers on the rail welding crane are lowered. While the train set is being repositioned, preparations for welding grinding are carried out simultaneously, and the straight section at the welding joint is bent.

[0049] S12. The booms of the containerized rail welding vehicles at both ends of the trainset rotate and extend outward to hoist the welding machine to the welding joint position. Simultaneously, flash welding and heat treatment are performed on the straight tracks before and after the turnout. After welding, the welded joints are ground and inspected for defects. After confirming that there are no abnormalities in the welding, the curved tracks of the turnout are connected by clamps. During the clamp installation, ground anchors are installed, electrical wiring is installed, fasteners are adjusted, and insulation bonding is performed simultaneously.

[0050] S13. The containerized rail welding vehicle 2 retracts its boom and outriggers in sequence and locks the vehicle assembly.

[0051] S14. By measuring parameters such as track gauge, direction, and level, the turnout is fine-tuned to ensure that the deviation between the relevant measurement results and the requirements of the construction operation technical plan is within the allowable range.

[0052] S15. While measuring and fine-tuning the turnouts, the outriggers of the dedicated flatcar for transporting turnout rail components in the train set are lowered and the loading fixtures are unlocked. Then, the folding boom crane on the flatcar is started to lift and retrieve the old turnout sections previously hoisted between the two tracks in the order of the turnout center section, the straight lower rail, and the point rail section. The turnout center section is placed on the first layer of the loading fixture, and the straight point rail and the straight lower rail are placed on the second layer. After the old turnout sections are hoisted, they are locked using the loading fixtures. Furthermore, the hoisting sequence for retrieving the old turnouts was already considered when the old turnout sections were hoisted between the two tracks.

[0053] S16. After the turnout fine-tuning and old turnout loading are completed, the construction site is inspected and confirmed to ensure that no personnel, machinery, or construction materials remain on site or encroach on the boundary. After inspection and confirmation, the cancellation procedures are completed, the track is returned to the pre-laying base, and the turnout replacement construction work is completed.

[0054] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0055] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. Specialized equipment for group replacement of high-speed railway turnouts, characterized in that: include: Traction power unit, welding operation unit, and turnout transportation unit; The traction power unit includes two heavy railcars (1), which are respectively assembled at the beginning and end of the entire train; The welding operation unit includes two containerized rail welding vehicles (2), which are respectively grouped inside the traction power unit; each containerized rail welding vehicle (2) is equipped with a rail welding vehicle folding boom crane (23), a flash welding machine (24), rail welding vehicle auxiliary outriggers (22), generator container (21), and welding machine crane power unit (25); the rail welding vehicle folding boom crane (23) is used to move the flash welding machine (24) to the adjacent rail joint for welding operation; The turnout transport unit includes several dedicated turnout transport flatcars (3) set between the first and last two welding operation units; each dedicated turnout transport flatcar (3) is equipped with at least two flatcar folding boom cranes (32), flatcar auxiliary outriggers (33), dedicated loading fixtures (31), and flatcar crane power units (34); the flatcar folding boom cranes (32) are used for lifting turnout rail components, and the dedicated loading fixtures (31) are used for layered loading and fixing of pre-laid turnout rail components; the dedicated turnout transport flatcar (3) is equipped with automatically lifting railings. The heavy railcar (1), container rail welding car (2) and special turnout transport flatcar (3) are connected by couplers to form an integrated operation group.

2. The special equipment for group replacement of high-speed railway turnouts according to claim 1, characterized in that: A large slewing bearing (321) is added to the lower part of the slewing device of the flatcar folding boom crane (32) on the dedicated turnout transport flatcar (3). A slewing reducer (322) is provided on the large slewing bearing (321). The base of the flatcar folding boom crane (32) is laterally changed relative to the frame through the large slewing bearing (321), so that the working range of the flatcar folding boom crane (32) covers the left or right adjacent line of the track.

3. The special equipment for group replacement of high-speed railway turnouts according to claim 2, characterized in that: The large slewing bearing (321) is replaced by a set of transverse guide rail mechanism, through which the transverse guide rail mechanism realizes the lateral movement and positioning of the flatcar folding boom crane (32) base.

4. The special equipment for group replacement of high-speed railway turnouts according to claim 1, characterized in that: The special loading fixture (31) includes at least two load-bearing structures: the first layer of rotating transverse support platform (312) is used to load the turnout section (5) of the rail assembly; the second layer of rotating transverse support platform (313) is used to load the straight tip rail section (4) and the curved lower rail (6) of the rail assembly; the rotating transverse support platform (312, 313) causes the rail assembly loaded on it to undergo the necessary transverse movement and rotation during transportation to adapt to the curved track and pass through.

5. The special equipment for group replacement of high-speed railway turnouts according to claim 4, characterized in that: The structure of the special loading fixture (31) includes a fixture slewing bearing (311) and a fixture support (314). The fixture slewing bearing (311) and the fixture support (314) are engaged with the chassis floor surface and can rotate around the slewing bearing on the chassis floor surface. A universal ball is installed at the lower part of the fixture support (314) to achieve rolling during fixture rotation while meeting the load-bearing requirements. The upper part of the fixture slewing bearing (311) and the fixture support (314) is provided with a first layer of slide rail (319) and a second layer of slide rail (320) from bottom to top. The lower part of the first layer of slide rail (319) is fixed to the fixture slewing bearing (311) and the fixture support (314). The first layer slide rail (319) is provided with a first layer rotating transverse support platform (312). The sliding plates on both sides of the first layer rotating transverse support platform (312) are slidably adapted to the slide groove on the first layer slide rail (319). The two ends of the first layer slide rail (319) are respectively provided with a long support positioning pin (316) and a short support positioning seat (317). One end of the second layer slide rail (320) is rotatably inserted into the long support positioning pin (316) through the pin hole. The other end of the second layer slide rail (320) is adapted to the single side of the short support positioning seat (317), so that the second layer slide rail (320) can rotate and move away around the long support positioning pin (316) in a specified direction. A drive cylinder (315) is installed between the long support positioning pin (316) and the second-layer slide rail (320). The drive cylinder can drive the second-layer slide rail (320) and the second-layer rotating transverse support (313) on it to rotate at a fixed angle, so as to facilitate the placement of rail components on the first-layer rotating transverse support (312). The second-layer slide rail (320) is provided with the second-layer rotating transverse support (313). The sliding plates on both sides of the second-layer rotating transverse support (313) are slidably adapted to the sliding groove on the second-layer slide rail (320). Locking devices (318) are provided on both the first-layer rotating transverse support (312) and the second-layer rotating transverse support (313).

6. The special equipment for group replacement of high-speed railway turnouts according to claim 1, characterized in that: The multiple flatcar folding boom cranes (32) on the dedicated turnout transport flatcar (3) are equipped with a synchronous control system; the synchronous control system includes a displacement sensor, a tension sensor and an angle encoder; the displacement sensor is used to collect displacement data of each lifting point and perform closed-loop control with displacement synchronization as the goal; the tension sensor is installed at the lifting point and is used to monitor the lifting force in real time and feed it back to the main control system for tension synchronization protection; the angle encoder is used to provide real-time feedback on the rotation angle of each flatcar folding boom crane (32) to achieve rotation synchronization control.

7. The special equipment for group replacement of high-speed railway turnouts according to claim 1, characterized in that: The rail welding vehicle folding boom crane (23) on the containerized rail welding vehicle (2) is also equipped with the synchronous control system and can realize the welding operation of adjacent rail joints within a maximum line spacing of 5.5m; the flatcar folding boom crane (32) on the special turnout transport flatcar (3) can realize the lifting operation of adjacent lines within a maximum line spacing of 5.5m.

8. A method for replacing high-speed railway turnouts in groups, using the special equipment described in any one of claims 1 to 7, characterized in that: Includes the following steps: S1. Transporting bulk rail components to the rail component pre-laying base; S2. Trains are assembled on the stop line of the pre-laying base according to the length of the extended rails of the turnout to be replaced, and the loose rail materials are assembled and pre-laid in the area next to the stop line. S3. Load the assembled and pre-laid rail components onto a dedicated turnout transport flatcar (3), with the turnout center section (5) on the first layer, and the straight tip section (4) and the curved lower rail (6) on the second layer; and use the dedicated loading fixture (31) on the flatcar for constraint and fixation. S4. After the track maintenance window opens, the train will run to the construction site and simultaneously carry out preparations for cutting old rails and removing ground anchors. S5. Train assembly and alignment on site, lowering the auxiliary outriggers on the dedicated turnout transport flatcar, and preparing for operation; S6. Using a flatcar folding boom crane (32), the cut old branch sections are lifted and placed in sequence between the two lines for temporary storage; S7. Reset the flatcar folding boom crane (32) and unlock the second layer of the special loading fixture (31); S8. Hoist the new straight tip rail section (4) and the curved lower rail (6) to the designated position and make fine adjustments for alignment; S9. Reset the flatcar folding boom crane (32), unlock the first layer of the special loading fixture (31), lift the turnout core section (5) to the designated position, and retract the auxiliary outriggers of the special turnout transport flatcar after completion; S10. Restore electrical equipment; S11. The train formation is slightly shifted so that the container-type rail welding car (2) is in place and the auxiliary outriggers (22) of the rail welding car are lowered. S12. Two containerized rail welding vehicles (2) simultaneously perform flash welding and heat treatment on the joints before and after the turnout; complete the joint grinding, flaw detection and connection work of the curved bar plate installation; S13. The containerized rail welding vehicle (2) retracts the boom and outriggers in sequence and locks the vehicle group; S14. Measure and fine-tune the track gauge, direction, and horizontal parameters of the turnout; S15. Lower the support legs (33) of the turnout transport flatcar, retrieve the old turnout sections and load and fix them onto the special turnout transport flatcar (3) in sequence; S16. After on-site inspection and confirmation, the train formation returns to the pre-laying base to complete the replacement operation.

9. A method for replacing high-speed railway turnouts in groups according to claim 8, characterized in that: In step S2 above, the pre-laying method in the base includes: S21. Place the special tooling for pre-laying rail components on the ground next to the pre-laying base stop line; S22. Based on the bolt hole location data of the turnout section to be replaced obtained from the on-site survey and mapping, accurately adjust the position of each pad on the pre-laid special tooling workbench; S23. Each dedicated turnout transport flatcar (3) in the train set is prepared for startup, and the flatcar auxiliary support legs (33) are lowered. S24. Use the flatcar folding boom crane (32) on the dedicated turnout transport flatcar (3) to lift the loose rail components onto the workbench of the pre-laid special tooling; S25. Adjust the position of the rail component pad according to the hole spacing of the pad on the workbench to complete the assembly and alignment of the turnout rail component bulk materials; S26. Based on the adhesive joint, the assembled and aligned rail components are welded to form three rail components: straight tip rail section (4), turnout section (5), and curved lower rail (6). S27. Perform flaw detection and static treatment on the three-section rail assembly after welding.

10. A method for replacing high-speed railway turnouts in groups according to claim 8, characterized in that: In step S3 above, the method for loading the group of rail components at the base includes: S31. The train sets are parked in place on the base parking line. Each dedicated turnout transport flatcar (3) is prepared to start up. The auxiliary outriggers (33) of the flatcar are lowered, and the large slewing bearing (321) and the slewing bearing of the load-bearing tooling of the flatcar folding boom crane (32) are adjusted to the appropriate lifting position. S32. Open the special loading fixture (31) on each special turnout transport flatcar (3), use the flatcar folding arm crane (32) to lift the group of rail components of the turnout section (5) at multiple points, and place them on the rotating transfer platform (312) of the first layer of the special loading fixture (31), and adjust their position so that they are as close as possible to the longitudinal center line of the flatcar. S33. Lock the first layer of the special loading fixture (31); S34. Using a flatcar folding arm crane (32), the group of rail components of the lower section (6) are lifted at multiple points and placed on the second layer of rotating transverse support platform (313) of the special loading fixture (31); S35. Use the flatcar folding arm crane (32) to lift the straight tip rail section (4) group rail components at multiple points, place them on the second layer rotating transverse support platform (313) of the special loading tool (31), and adjust their position so that their center of gravity is as close as possible to the longitudinal center line of the flatcar. S36. Retract each flatcar folding boom crane (32) and flatcar auxiliary outriggers (33) to the transport position in sequence; S37. Lock the second layer of the special loading fixture (31) to complete the loading.

Images