Double-block type sleeper suitable for urban railways and interurban railways and production process of double-block type sleeper
By introducing pre-embedded sleeves into the sleepers and optimizing the steel reinforcement skeleton structure, combined with high-performance concrete pouring technology, the problems of traditional sleepers being heavy, costly, and complex to construct have been solved, achieving lightweight and efficient track structure stability.
Patent Information
- Application Number
- CN202511458840.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-13
- Publication Date
- 2025-12-16
AI Technical Summary
Traditional double-block sleeper structures are bulky, require a large amount of materials, have high production costs, and are complex to construct. They are difficult to meet the long-term load requirements of urban and intercity railways, and the shoulder area is prone to stress concentration damage.
The concrete sleeper is equipped with pre-embedded sleeves and a steel reinforcement skeleton, including steel trusses and shoulder reinforcement steel mesh. The steel reinforcement design and concrete usage are optimized. Combined with high-performance concrete pouring and steam curing technology, a lightweight double-block sleeper is formed.
The reduction in sleeper thickness and material usage improved impact resistance and compressive bearing capacity, reduced transportation and construction costs, and ensured the long-term stability and pull-out resistance of the track structure.
Smart Images
Figure CN121138076A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the field of railway track engineering, in particular to a double-block sleeper suitable for city-region railways and intercity railways and a production process thereof. BACKGROUND
[0002] In the existing city development and traffic network construction, city-region railways and intercity railways play an indispensable role. These two types of railways serve the internal and inter-city commuting of cities, and different levels of travel demand. The double-block sleeper is a key component in the railway ballastless track system. The traditional double-block sleeper has problems such as heavy structure, large amount of material, high production cost, and complex on-site installation and adjustment process. Especially for the long-term cyclic load requirements of city-region and intercity lines, the present sleeper greatly improves the bearing capacity and strengthens the anti-pulling force of the embedded sleeve. In addition, the shoulder part of the traditional sleeper is prone to stress concentration and damage under train load.
[0003] Therefore, there is an urgent need for a sleeper structure and production method that can realize lightweight, low cost and simplify construction while ensuring or even improving performance. SUMMARY
[0004] The purpose of the present application is to provide a double-block sleeper suitable for city-region railways and intercity railways and a production process thereof, which can overcome the above-mentioned defects of the prior art.
[0005] To solve the above technical problems, the present application adopts the following technical solutions:
[0006] A double-block sleeper for city-region railways and intercity railways, comprising a pair of concrete sleepers connected by a truss steel reinforcement framework, wherein an embedded sleeve is arranged in the concrete sleeper;
[0007] The steel reinforcement framework comprises two groups of parallel steel trusses, a pair of concrete sleepers are provided with rail shoulders, and the concrete sleeper is provided with an independent shoulder reinforcing steel mesh at the position corresponding to the rail shoulder.
[0008] The thickness of the concrete sleeper block is less than or equal to that of the conventional sleeper of the same type, and the total amount of material of a single sleeper is 19.8 kg of steel reinforcement and 0.068 cubic meters of C60 concrete.
[0009] Preferably, each group of steel trusses comprises three main reinforcements and two wave reinforcements, and the three main reinforcements are distributed as follows: one group at the top and two groups at the bottom, which are connected and fixed by the wave reinforcements to form a triangular structure.
[0010] Preferably, the shoulder reinforcing steel mesh is a three-dimensional bent structure, and the contour thereof matches the shape of the inner surface of the rail shoulder of the concrete sleeper.
[0011] Preferably, the shoulder reinforcing steel mesh comprises a pair of outer support bars, a plurality of stirrups and fastener bars for fixing the connecting nodes, and the pair of outer support bars are connected and fixed by the plurality of stirrups.
[0012] A pair of shoulder reinforcing bars are further fixed and connected on the plurality of stirrups.
[0013] Preferably, the number of the embedded sleeves is four, which are symmetrically arranged in the concrete sleeper.
[0014] Preferably, a process for producing a double-block sleeper comprises the following steps:
[0015] S1: mold preparation, cleaning the long-line pedestal mold and installing the embedded sleeve positioning rod;
[0016] S2: steel assembly, placing the two groups of prefabricated steel trusses and two shoulder reinforcing steel meshes into the mold to form an overall steel framework;
[0017] S3: concrete pouring, pouring C60 high-performance concrete into the mold;
[0018] S4: vibration forming, vibrating the mold with a variable frequency vibrator to make the concrete dense;
[0019] S5: curing, steam curing the poured sleeper;
[0020] S6: demolding and storage, after the concrete strength reaches the specified value, the mold is removed to obtain the finished sleeper.
[0021] Preferably, in S3, the C60 high-performance concrete is self-compacting concrete.
[0022] Preferably, in S4, the vibration uses a directional attached vibrator, which focuses on vibrating the areas of the embedded sleeves and the shoulder reinforcing steel mesh.
[0023] Preferably, in S5, the steam curing includes four stages of static stop, temperature rise, constant temperature and temperature drop, the constant temperature is controlled at 50-60℃, and the constant temperature time is not less than 4 hours.
[0024] Preferably, in S2, the steel truss and the shoulder reinforcing steel mesh are prefabricated by resistance spot welding.
[0025] Compared with the prior art, the present application has the following advantages:
[0026] The double-block sleeper of the present application reduces the thickness of the sleeper, directly reduces the amount of concrete, optimizes the design of the steel bar, and the combined action of the reinforcing mesh and the optimized steel bar truss greatly improves the impact resistance of the sleeper shoulder and the overall compressive bearing capacity. The high density of the concrete around the sleeve ensures its extraordinary pullout resistance, ensuring the long-term stability of the track structure. At the same time, the self-weight of the product is reduced, reducing the difficulty and cost of transportation and on-site hoisting and laying, and reducing the on-site operation process and intensity. BRIEF DESCRIPTION OF DRAWINGS
[0027] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.
[0028] Figure 1 is a sectional view of a double-block sleeper suitable for a city railway and an intercity railway of the present application,
[0029] Figure 2 is a top view of a double-block sleeper suitable for a city railway and an intercity railway of the present application,
[0030] Figure 3 is a front view of a shoulder reinforcing steel mesh of a double-block sleeper suitable for a city railway and an intercity railway of the present application,
[0031] Figure 4 is a top view of a shoulder reinforcing steel mesh of a double-block sleeper suitable for a city railway and an intercity railway of the present application,
[0032] Figure 5 is a front view of a fastener steel bar of a double-block sleeper suitable for a city railway and an intercity railway of the present application,
[0033] Figure 6 is a side sectional view of a double-block sleeper suitable for a city railway and an intercity railway of the present application.
[0034] In the figure: 10, concrete sleeper block; 11, rail shoulder; 12, embedded sleeve; 20, steel bar truss; 21, main reinforcement; 22, secondary reinforcement; 30, shoulder reinforcing steel mesh; 31, outer support bar; 32, stirrup; 33, shoulder reinforcing steel bar; 34, fastener steel bar. DETAILED DESCRIPTION
[0035] With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.
[0036] As shown in the embodiment, the present application provides a double-block sleeper for city region railway and intercity railway, which comprises a pair of concrete sleeper blocks 10 and a steel reinforcement framework connecting the pair of concrete sleeper blocks 10, which is the basic structure form of the double-block sleeper. Two independent sleeper blocks are connected into a whole through the steel reinforcement framework, which not only ensures the continuity and stability of the subgrade, but also greatly reduces the weight compared with the integral concrete sleeper, facilitating transportation and laying. The steel reinforcement framework is the transmission link of force, which transmits the load applied on one sleeper block by the train wheel hub to the other sleeper block and the further subgrade, so that the stress is more uniform and the local stress is reduced. Figures 1-6 As shown in the embodiment, the concrete sleeper block 10 is provided with a pre-embedded sleeve pipe 12, and the number of the pre-embedded sleeve pipe 12 is four, which are symmetrically arranged in the pair of concrete sleeper blocks 10. The pre-embedded sleeve pipe is the only interface for connecting the sleeper and the rail fastener system, and its function is to accurately fix and install the fastener components such as elastic strips and bolts. The positioning accuracy of the sleeve pipe directly determines the gauge and level geometry of the rail. The present application pre-embeds the sleeve pipe in the concrete, which ensures the permanence and firmness of the connection. The material of the sleeve pipe is usually high-strength nylon or metal, and the inner thread or other self-locking structure is adopted to provide the pullout resistance.
[0037] Figure 2 As shown in the embodiment, the steel reinforcement framework comprises two groups of steel reinforcement trusses 20 arranged in parallel, and each group of steel reinforcement trusses 20 comprises three main reinforcements 21 and a plurality of secondary reinforcements 22. The positions of the three main reinforcements 21 are distributed as follows: one group at the top and two groups at the bottom, which are connected and fixed through the plurality of secondary reinforcements 22, forming an isosceles triangle structure. This asymmetric arrangement of "one on top and two on the bottom" is the result of deep understanding of the stress mode of the sleeper.
[0038] As shown in the embodiment, the steel reinforcement framework comprises two groups of steel reinforcement trusses 20 arranged in parallel, and each group of steel reinforcement trusses 20 comprises three main reinforcements 21 and a plurality of secondary reinforcements 22. The positions of the three main reinforcements 21 are distributed as follows: one group at the top and two groups at the bottom, which are connected and fixed through the plurality of secondary reinforcements 22, forming an isosceles triangle structure. This asymmetric arrangement of "one on top and two on the bottom" is the result of deep understanding of the stress mode of the sleeper. Figure 6 Firstly, the train load is transmitted to the sleeper block through the rail and the fastener, which is mainly a downward pressure. This pressure will make the steel reinforcement truss connecting the two sleeper blocks bear a bending moment, and the upper part of the truss is in tension and the lower part is in compression. The concrete has good compressive resistance but poor tensile resistance, so steel reinforcement is needed to resist tension.
[0039]
[0040] Secondly, the upper group of main reinforcement 21 is arranged at the top of the truss, mainly to bear the tensile stress caused by the bending moment. It is a tensile main reinforcement 21. The lower two groups of main reinforcement 21 are arranged on both sides of the bottom of the truss. They have three functions: ① jointly serve as a compressive main reinforcement 21 to bear the compression; ② more importantly, they form a wider base, greatly enhancing the truss's ability to resist lateral instability and improving overall stability; ③ provide more connection nodes for the secondary reinforcement, making the truss structure more stable.
[0041] In contrast to the traditional symmetrical structure, the traditional truss is often symmetrical up and down, such as two on top and two on the bottom. The "triangular" asymmetric structure of the present invention has a lower center of gravity and better stability, especially good at resisting lateral sway forces generated during train operation, and is particularly suitable for the characteristics of city region trains that start and stop quickly.
[0042] It is worth noting that the "triangle" is a classic stable form in structural mechanics. It converts the internal stress of the truss into axial force along the direction of the secondary reinforcement, avoiding complex bending stress, making the force transmission path clear and efficient. This structure can provide the maximum stiffness and stability under a given amount of material.
[0043] As shown in Figure 1 and Figure 3 , a pair of concrete sleeper blocks 10 are provided with rail shoulders 11 on both sides, and independent shoulder reinforcing steel mesh 30 is embedded in the concrete sleeper blocks 10 at the positions corresponding to the rail shoulders 11. The shoulder reinforcing steel mesh 30 is a separate component designed specifically to strengthen the shoulder and is not an accessory part of the main steel truss. This means that its shape, steel diameter and arrangement can be customized according to the stress characteristics of the shoulder, achieving the specificity of function and the accuracy of design. The shoulder reinforcing steel mesh 30 is embedded in the most critical stress area inside the shoulder, closely following the lower and outer sides of the embedded sleeve. The internal concrete is constrained by a network of high-strength steel, which can effectively bear tensile stress when the concrete is subjected to lateral pressure, thereby greatly inhibiting the generation and propagation of concrete micro-cracks and preventing brittle failure of the shoulder, significantly improving the durability and reliability of the sleeper.
[0044] The shoulder reinforcing steel mesh 30 is a three-dimensional bent structure, and its contour matches the shape of the inner surface of the rail shoulder 11 of the concrete sleeper block 10. The shoulder is a three-dimensional, irregular complex geometric body that bears forces from multiple directions. A flat steel mesh cannot fit it and the strengthening effect is limited. "Three-dimensional bending" means that the mesh is cold-bent according to the three-dimensional digital model or mold shape of the shoulder cavity in advance. It is not a flat surface, but a complex three-dimensional component in the shape of a "basket" or "cage". This ensures that every steel bar in the mesh is in the most ideal position and can most effectively intercept and bear cracks and stresses from different directions.
[0045] As shown in Figure 4 and Figure 5 The shoulder reinforcing steel mesh 30 includes a pair of outer support bars 31, a plurality of stirrups 32 and fastener steel bars 34 for fixing the connection nodes, and the pair of outer support bars 31 are connected and fixed by the plurality of stirrups 32. The pair of outer support bars 31 and the plurality of stirrups 32 constitute the main frame and the external contour of the mesh.
[0046] A pair of shoulder reinforcing steel bars 33 are also fixed and connected on the plurality of stirrups 32. The shoulder reinforcing steel bars 33 are arranged at the key position where the stress is most concentrated and most likely to be damaged, that is, on the path with the highest stress corresponding directly to the bottom side of the rail. It can be a slightly thicker steel bar or a group of steel bars, which are welded on the frame composed of the outer support bars 31 and the stirrups 32. Through the shoulder reinforcing steel bars 33, the key area is reinforced, ensuring that even under extreme load, the area remains intact.
[0047] The thickness of the concrete sleeper block 10 is less than or equal to that of the conventional similar sleeper, and the total amount of material for a single sleeper is 19.8 kg of steel bars 19 and 0.068 cubic meters of C60 concrete. The traditional design often increases the thickness to make up for the lack of bending and tensile resistance. The present application uses ingenious steel bar arrangement to make the steel bars bear tensile stress, and the concrete mainly bears compressive stress, so the amount of concrete can be reduced. That is, through the optimization design of the above-mentioned steel truss and independent shoulder mesh, the carrying capacity and crack resistance of the whole sleeper not only do not decrease, but on the contrary, they are improved. This means that we can use less concrete material to achieve the same or even higher safety standards.
[0048] A process for producing a double-block sleeper, comprising the following steps:
[0049] S1: mold preparation, cleaning the long-line pedestal mold and installing the pre-buried sleeve positioning rod;
[0050] S2: steel bar assembly, placing the two groups of prefabricated steel trusses 20 and two shoulder reinforcing steel meshes 30 into the mold to form an overall steel framework. The steel truss 20 and the shoulder reinforcing steel mesh 30 are prefabricated by resistance spot welding.
[0051] S3: concrete pouring, pouring C60 high-performance concrete into the mold, wherein the C60 high-performance concrete is self-compacting concrete.
[0052] S4: vibration forming, using a variable frequency vibrator to vibrate the mold to make the concrete dense. Directional adhesion type vibrator is used, and the areas of the pre-buried sleeve 12 and the shoulder reinforcing steel mesh 30 are vibrated.
[0053] S5: curing, the sleeper after pouring is carried out steam curing, and the steam curing includes four stages of static stopping, temperature rising, constant temperature and temperature falling, the constant temperature is controlled at 50-60 DEG C, and the constant temperature time is not less than 4 hours.
[0054] The static stopping is to place at room temperature for 2-3 hours after pouring, and the purpose is to let the concrete preliminarily coagulate and obtain certain initial structural strength, so as to avoid structural damage caused by internal pore water expansion due to heating in the temperature rising stage. The constant temperature is to keep at 50-60 DEG C for at least 4 hours, which is the main stage of rapid strength growth, and the temperature interval is the optimal selection of experience and technology, too low temperature cannot obviously accelerate the effect, and too high temperature can cause weak post-strength growth of the concrete and durability decline. The temperature falling is to slowly fall to room temperature at a controllable speed, and rapid temperature falling can also cause cracks due to thermal expansion and cold shrinkage, and slow temperature falling can make the internal structure of the concrete smoothly transit.
[0055] S6: demolding and storage, after the concrete strength reaches the specified value, the mold is removed, and the finished sleeper is obtained.
[0056] The double-block sleeper reduces the thickness of the sleeper, directly reduces the concrete consumption, optimizes the steel bar design, reduces the steel consumption, reduces the raw material cost from the source, lightens the product self-weight, reduces the difficulty and cost of transportation and on-site hoisting and laying, and reduces the on-site operation process and strength.
[0057] The reinforcing mesh and the optimized steel bar truss work together, greatly improve the impact resistance of the sleeper shoulder and the overall compressive bearing capacity, the high density of the concrete around the sleeve ensures the excellent anti-pulling force, and guarantees the long-term stability of the track structure.
[0058] Obviously, those skilled in the art can make various modifications and changes to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and changes of the present application belong to the scope of the claims of the present application and the equivalent technology thereof, the present application also intends to include these modifications and changes.
Claims
1. A double-block sleeper for urban and intercity railways, characterized in that, A single sleeper consists of a pair of truss steel reinforcement frames connected in the middle of a concrete sleeper, and a pre-embedded sleeve is installed inside the concrete sleeper. The steel reinforcement frame includes two sets of parallel steel trusses. Each concrete sleeper is provided with a rail shoulder. An independent shoulder reinforcement steel mesh is built into the concrete sleeper at the position corresponding to the rail shoulder. The thickness of the concrete sleeper block is less than or equal to that of a traditional sleeper of the same type, and the total material usage of a single sleeper is 19.8 kg of steel reinforcement and 0.068 cubic meters of C60 concrete.
2. The double-block sleeper for urban and intercity railways as described in claim 1, characterized in that, Each set of steel trusses includes three main bars and two corrugated bars. The three main bars are distributed as follows: one set at the top and two sets at the bottom. They are connected and fixed by the corrugated bars to form a triangular structure.
3. The double-block sleeper for urban and intercity railways as described in claim 1, characterized in that, The shoulder reinforcement mesh is a three-dimensional bent structure, and its outline matches the shape of the inner surface of the rail shoulder of the concrete sleeper.
4. The double-block sleeper for urban and intercity railways as described in claim 3, characterized in that, The shoulder reinforcement steel mesh includes a pair of outer support bars, several stirrups, and fastener steel bars for fixing the connection nodes. The pair of outer support bars are connected and fixed by several stirrups. A pair of shoulder reinforcing bars are also fixedly connected to several of the stirrups.
5. The double-block sleeper for urban and intercity railways as described in claim 1, characterized in that, The number of pre-embedded sleeves is four, symmetrically arranged in a pair of concrete sleepers.
6. A process for producing the double-block sleeper as described in any one of claims 1-5, characterized in that, Includes the following steps: S1: Mold preparation, cleaning the long line platform mold and installing the pre-embedded sleeve positioning rod; S2: Reinforcing steel assembly: Place the two prefabricated sets of steel trusses and two shoulder reinforcement steel meshes into the mold to form an overall steel skeleton; S3: Concrete pouring, pouring C60 high-performance concrete into the mold; S4: Vibration molding, using a high-frequency vibrator to vibrate the mold to make the concrete dense; S5: Curing, steam curing of the sleepers after casting; S6: Demolding and storage. After the concrete strength reaches the design value, the mold is removed to obtain the finished sleeper.
7. The manufacturing process for the double-block sleeper as described in claim 6, characterized in that, In S3, the C60 high-strength concrete.
8. The manufacturing process for the double-block sleeper as described in claim 6, characterized in that, In S4, the vibration is achieved using a directional attachment type vibrator.
9. The manufacturing process for the double-block sleeper as described in claim 6, characterized in that, In step S5, the steam curing includes four stages: static shutdown, heating, constant temperature and cooling. The constant temperature is controlled at 50℃-60℃, and the constant temperature time is not less than 4 hours.
10. The manufacturing process for the double-block sleeper as described in claim 6, characterized in that, In S2, the steel truss and the shoulder reinforcement steel mesh are prefabricated by resistance spot welding.