A high-speed railway double-block type ballastless track bed modular construction method

Abstract

The application relates to the field of rail transit construction technology, in particular to a high-speed railway double-block type ballastless track bed modular construction method, which comprises base plate construction and track bed plate construction, and has the beneficial effect that: the modularized track rack, the steel bar assembly and the prefabricated formwork are arranged, so that the mechanization, the intelligentization and the standardization construction of the double-block type ballastless track bed construction mode are realized; the strength and the rigidity of the plate type track rack are relatively high compared with those of the traditional nested track rack; the high-strength structure design is easy to control the overall installation deformation, and the track bed plate construction precision and quality are ensured; the steel bar assembly and the prefabricated formwork can be integrally hoisted and disassembled during the construction process, so that the construction efficiency is improved, and the modular construction of key processes such as the ballastless track bed steel bar construction, the formwork transfer installation and the track rack assembly installation is realized.

Description

Technical Field

[0001] This invention relates to the field of rail transit construction technology, specifically to a modular construction method for high-speed railway double-block ballastless track bed. Background Technology

[0002] The traditional construction method of double-block ballastless track bed adopts the manual in-situ flow operation mode: (1) using CPⅢ measurement control points to complete the beam surface layout work; (2) binding the base plate reinforcement; (3) setting up the base plate side formwork, edge sealing formwork, and groove formwork; (4) concrete pouring, vibration, and finishing; (5) concrete curing; (6) base plate formwork removal and transportation; (7) geotextile laying and elastic support installation; (8) tying the groove reinforcement and lower reinforcement of the track bed slab; (9) loose sleepers and cloth sleepers; (10) track bed slab formwork setting; (11) track panel assembly; (12) track bed slab upper reinforcement binding; (13) concrete pouring, vibration, and finishing; (14) concrete curing; (15) track panel and formwork removal and transportation; This traditional construction method has the following drawbacks.

[0003] (1) Traditional construction production organization is mainly based on in-situ flow operation, and the construction method is mainly labor-intensive operation, with high risk of cross-operation;

[0004] (2) Low level of mechanization, lack of intelligence, and low construction efficiency;

[0005] (3) The final accuracy of track geometry (elevation, level, track orientation, track gauge) is highly dependent on manual measurement, resulting in low engineering quality control methods and significant quality instability;

[0006] (4) The formwork, steel bars, sleepers and other materials occupy a large area and the materials are piled up in a mess on the work surface, which poses a high risk of safety hazards. Summary of the Invention

[0007] The purpose of this invention is to provide a modular construction method for high-speed railway double-block ballastless track bed to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] A modular construction method for high-speed railway double-block ballastless track bed, the method comprising the following steps:

[0010] Step 1: Base plate construction;

[0011] S1: Beam surface treatment and layout:

[0012] The beam surface scanning vehicle scans the beam surface data and transmits it to the layout vehicle, which then completes the layout of the template edge line, the rebar edge line, and the center of the limiting groove template.

[0013] S2: Reinforcement and formwork construction:

[0014] The modular lower-layer steel reinforcement components are assembled and hoisted onto the working beam surface using a steel reinforcement work trolley, and the prefabricated lower-layer casting formwork is hoisted onto the outside of the lower-layer steel reinforcement components using a formwork work trolley.

[0015] S3: Concrete pouring:

[0016] The inner cavity enclosed by the base plate casting template is poured, vibrated, and finished, and then fully cured.

[0017] S4: Geotextile laying:

[0018] After curing, the template components are demolded and transported using a template work trolley, and then geotextile is laid on the upper surface of the formed base plate.

[0019] Step 2: Construction of the track bed slab;

[0020] N1: Loose pillow, spread-out pillow:

[0021] The foundation data of the base plate to be constructed is measured by scanning the trolley and sent to the assembly platform. The upper layer of steel reinforcement components are laid on the assembly platform composed of geotextile and limiting groove using the steel reinforcement operation trolley. The automatic sleeper dispersing device on the mobile operation trolley is used to lay the sleepers at intervals on the assembly platform.

[0022] N2: Rail panel installation:

[0023] The prefabricated modular rail frame is hoisted onto the sleeper using a rail frame transfer trolley, and the rail frame is roughly adjusted so that its position relative to the sleeper meets the construction standards.

[0024] N3: Installation of formwork for track bed slab pouring:

[0025] The upper-level casting formwork is installed on the outside of the upper-level steel reinforcement assembly using a formwork work trolley, and the plate-type track frame and the upper-level casting formwork are finely adjusted.

[0026] N4: Casting and molding;

[0027] The inner cavity enclosed by the upper casting formwork is filled with concrete, vibrated and finished. After molding, it is fully cured. After curing, the formwork is removed and the platen track frame is disassembled as a whole and transported to the next process.

[0028] Preferably, the lower and upper steel reinforcement components adopt a mesh design, which consists of three sets of steel reinforcement mesh modules: an upper steel reinforcement mesh, a lower steel reinforcement mesh, and an edge-sealing steel reinforcement mesh. The three sets of steel reinforcement mesh modules are assembled and tied by a steel reinforcement work trolley, and the assembled steel reinforcement components are hoisted to the working beam surface using the hoisting device built into the steel reinforcement work trolley.

[0029] Preferably, the assembly process of the reinforcing steel assembly is as follows: Step 1: Construction preparation; Step 2: Positioning of the moving bracket; Step 3: Hoisting of the lower reinforcing steel mesh; Step 4: Hoisting of the edge-sealing frame reinforcing steel mesh; Step 5: Hoisting of the upper reinforcing steel mesh; Step 6: Assembly of the reinforcing steel cage; Step 7: Hoisting of the reinforcing steel assembly. The specific assembly method is as follows:

[0030] Positioning of the mobile bracket: The mobile bracket moves to the corresponding position in sequence according to the bracket support point position;

[0031] Lower steel mesh hoisting: The lower steel bars are hoisted to the mobile bracket using a special steel bar hoisting tool;

[0032] Erection of the edge-sealing steel mesh: The dual-degree-of-freedom control mechanism adjusts the position of the rotating bracket according to the elevation and support point of the upper steel bar, and lifts the erected steel bar;

[0033] Upper steel mesh hoisting: The upper steel bars are hoisted to the mobile bracket using specialized steel bar hoisting equipment;

[0034] Rebar assembly: Rebar assembly is completed using robotic arms for hoisting and mobile binding / welding robots;

[0035] Reinforcing bar assembly hoisting: hoisting to the beam surface using specialized reinforcing bar hoisting equipment.

[0036] Preferably, the lower layer casting template includes a base plate casting template and a limiting groove template. After the limiting groove template is removed, the geotextile at that position is cut, and then the cut geotextile is placed at the bottom of the formed limiting groove. Elastic gaskets are then glued to the side of the limiting groove, and the gaps between the glued areas are sealed with tape.

[0037] Preferably, the upper casting template is a track bed slab casting template, and both the upper and lower casting templates are prefabricated templates with magnetic connection.

[0038] Preferably, the plate-type track frame includes a main steel frame, which is used to simulate the track to be laid. The main steel frame is installed on the double-block sleepers by steel pads.

[0039] Preferably, the outer side of the main steel frame is provided with four sets of legs fixed to the bridge deck, and an adjustment assembly is provided between the legs and the main steel frame. The adjustment assembly includes a longitudinal adjustment device for adjusting the longitudinal position of the plate-type track frame and a lateral adjustment device for adjusting the lateral position.

[0040] Preferably, the slab track frame is equipped with measuring components for fine-tuning the sleeper grooves. The measuring components are configured in four sets, and the four sets of measuring components are respectively installed on the outside of the second sleeper and the penultimate sleeper in the double-block ballastless track construction section.

[0041] Compared with the prior art, the beneficial effects of the present invention are:

[0042] This invention achieves mechanized, intelligent, and standardized construction of a double-block ballastless track bed by setting up modular track panels, steel reinforcement components, and prefabricated templates. The slab-type track panels have higher strength and rigidity than traditional nested track panels, and the high-strength structural design makes it easy to control overall installation deformation, ensuring the accuracy and quality of track bed construction. The steel reinforcement components and prefabricated templates can be hoisted and disassembled as a whole during construction, thereby improving construction efficiency and realizing modular construction of key processes such as steel reinforcement construction, template transportation and installation, and track panel component installation for ballastless track beds. Attached Figure Description

[0043] Figure 1 This is a three-dimensional structural diagram of the lower-layer steel reinforcement assembly of the present invention;

[0044] Figure 2 This is a schematic diagram of the three-dimensional structure of the edge-sealing steel mesh of the present invention;

[0045] Figure 3 This is a flowchart of the construction method of the present invention;

[0046] Figure 4 This is a flowchart of the steel reinforcement assembly method of the present invention;

[0047] Figure 5 This is a side view of the plate-type track frame of the present invention;

[0048] Figure 6 This is a schematic diagram of the three-dimensional structure of the prefabricated template of the present invention.

[0049] In the diagram: 1. Support leg; 2. Main steel frame; 3. Longitudinal adjustment device; 4. Lateral adjustment device; 9. Upper steel mesh; 10. Lower steel mesh; 20. Edge sealing steel mesh; 30. Precast formwork. Detailed Implementation

[0050] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0051] Please see Figures 1 to 6 The present invention provides a technical solution:

[0052] A modular construction method for high-speed railway double-block ballastless track bed, the method comprising the following steps:

[0053] Step 1: Base plate construction;

[0054] S1: Beam surface treatment and layout:

[0055] The beam surface scanning vehicle scans the beam surface data and transmits it to the layout vehicle, which then completes the layout of the template edge line, the rebar edge line, and the center of the limiting groove template.

[0056] S2: Reinforcement and formwork construction:

[0057] The modular lower-layer steel reinforcement components are assembled and hoisted onto the working beam surface using a steel reinforcement work trolley. The prefabricated lower-layer casting template is hoisted onto the outside of the lower-layer steel reinforcement components using a template work trolley. The lower-layer casting template includes a base plate casting template and a limiting groove template.

[0058] S3: Concrete pouring:

[0059] The inner cavity enclosed by the base plate casting template is poured, vibrated, and finished, and then fully cured.

[0060] S4: Geotextile laying:

[0061] After the curing is completed, the template components are demolded and transported using a template work trolley. Then, geotextile is laid on the upper surface of the formed base plate. After the template of the limiting groove is removed, the geotextile at this position is cut. The cut geotextile is then placed at the bottom of the formed limiting groove, and elastic gaskets are glued to the side of the limiting groove. The gaps between the glued areas are sealed with tape.

[0062] Step 2: Construction of the track bed slab;

[0063] N1: Loose pillow, spread-out pillow:

[0064] The foundation data of the base plate to be constructed is measured by scanning the trolley and sent to the assembly platform. The upper layer of steel reinforcement components is laid on the assembly platform composed of geotextile and limiting grooves using the steel reinforcement operation trolley. The automatic sleeper dispersing device on the mobile operation trolley is used to lay sleepers at intervals on the assembly platform. The lower and upper steel reinforcement components adopt a mesh design, which consists of three sets of steel reinforcement mesh modules, namely upper steel reinforcement mesh, lower steel reinforcement mesh, and edge-sealing erected steel reinforcement mesh. The three sets of steel reinforcement mesh modules are assembled and tied by the steel reinforcement operation trolley. The assembled steel reinforcement components are hoisted to the working beam surface using the hoisting tool built into the steel reinforcement operation trolley.

[0065] The assembly process for the rebar assembly is as follows: Step 1: Construction preparation; Step 2: Positioning of the moving bracket; Step 3: Hoisting of the lower rebar mesh 10; Step 4: Hoisting of the edge-sealing rebar mesh 20; Step 5: Hoisting of the upper rebar mesh 9; Step 6: Rebar cage assembly; Step 7: Rebar assembly hoisting. The specific assembly method is as follows:

[0066] Positioning of the mobile bracket: The mobile bracket moves to the corresponding position in sequence according to the bracket support point position;

[0067] Lower steel mesh 10 hoisting: The lower steel bars are hoisted to the mobile bracket using a special steel bar hoisting tool;

[0068] 20mm edge-sealing steel mesh hoisting: The dual-degree-of-freedom control mechanism adjusts the position of the rotating bracket according to the elevation position of the upper steel bar and the support point of the upper steel bar, and lifts the erected steel bar;

[0069] Upper steel mesh 9 hoisting: The upper steel bars are hoisted to the mobile bracket using special steel bar hoisting equipment;

[0070] Rebar assembly: Rebar assembly is completed using robotic arms for hoisting and mobile binding / welding robots;

[0071] Reinforcing bar assembly hoisting: hoisting to the beam surface using specialized reinforcing bar hoisting equipment.

[0072] N2: Rail panel installation:

[0073] The modular slab track frame is hoisted onto the sleepers using a track frame transfer trolley, and coarse adjustments are made to ensure its position relative to the sleepers meets construction standards. The slab track frame includes a main steel frame 2, which simulates the track to be laid. The main steel frame 2 is mounted on the double-block sleepers via steel pads. Four sets of support legs 1, fixed to the bridge deck, are installed on the outer side of the main steel frame 2. An adjustment assembly is provided between the support legs 1 and the main steel frame 2, including a longitudinal adjustment device 3 for adjusting the longitudinal position of the slab track frame and a lateral adjustment device 4 for adjusting the lateral position. Four sets of measuring components are installed on the slab track frame for fine-tuning the sleeper groove measurements. These four sets of measuring components are respectively located on the outer side of the second sleeper and the penultimate sleeper in the double-block ballastless track section.

[0074] N3: Installation of formwork for track bed slab pouring:

[0075] The upper casting template is installed on the outside of the upper steel reinforcement assembly by a template operation trolley. The upper casting template is the track bed slab casting template. Both the upper and lower casting templates are prefabricated templates 30 with magnetic connection. The slab track frame and the upper casting template are finely adjusted.

[0076] N4: Casting and molding;

[0077] The inner cavity enclosed by the upper casting formwork is filled with concrete, vibrated and finished. After molding, it is fully cured. After curing, the formwork is removed and the platen track frame is disassembled as a whole and transported to the next process.

[0078] Working principle: The construction method is divided into base plate construction and track bed slab construction. During the base plate construction, the beam surface scanning operation vehicle scans the beam surface data and transmits it to the layout operation vehicle. The detection data is used to determine the layout position, thereby determining the installation position of subsequent construction equipment, including the installation position of equipment such as formwork and steel reinforcement components. Then, the steel reinforcement operation trolley is used to assemble the lower layer steel reinforcement components. Through the design of the mesh modular steel reinforcement structure, the lower layer steel reinforcement components can be easily assembled and tied, thus forming a prefabricated integral lower layer steel reinforcement component. Then, the hoisting equipment is used to lift it as a whole to the edge position determined by the layout. After the hoisting is completed, the modular formwork is assembled into an integral prefabricated formwork 30 using the formwork operation trolley. The whole formwork is then lifted by the hoisting equipment. After precise adjustment of the position, concrete is poured and cured. Finally, the formwork is removed and geotextile is laid.

[0079] After the base plate is formed, the track bed slab is constructed on top of it. The foundation data of the base plate to be constructed is measured by scanning trolley. Based on the collected data, the upper steel reinforcement components are assembled, tied, and hoisted using a steel reinforcement operation trolley. The sleepers are laid at intervals using an automatic sleeper dispersing device on a mobile operation trolley. The pre-formed modular slab track frame is hoisted onto the sleepers using a track frame transfer trolley. The hoisting position is precisely adjusted using adjustment components, and the installation position is precisely measured using measuring components. The upper pouring formwork is installed on the outside of the upper steel reinforcement components using a template operation trolley, and concrete is poured, cured, and formed. Finally, the track frame and template are dismantled and transported to the next process, forming a continuous modular intelligent construction.

[0080] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A modular construction method for high-speed railway double-block ballastless track bed, characterized in that: The construction method includes the following steps: Step 1: Base plate construction; S1: Beam surface treatment and layout: The beam surface scanning vehicle scans the beam surface data and transmits it to the layout vehicle, which then completes the layout of the template edge line, the rebar edge line, and the center of the limiting groove template. S2: Reinforcement and formwork construction: The modular lower-layer steel reinforcement components are assembled and hoisted onto the working beam surface using a steel reinforcement work trolley, and the prefabricated lower-layer casting formwork is hoisted onto the outside of the lower-layer steel reinforcement components using a formwork work trolley. S3: Concrete pouring: The inner cavity enclosed by the base plate casting template is poured, vibrated, and finished, and then fully cured. S4: Geotextile laying: After curing, the template components are demolded and transported using a template work trolley, and then geotextile is laid on the upper surface of the formed base plate. Step 2: Construction of the track bed slab; N1: Loose pillow, spread-out pillow: The foundation data of the base plate to be constructed is measured by scanning the trolley and sent to the assembly platform. The upper layer of steel reinforcement components are laid on the assembly platform composed of geotextile and limiting groove using the steel reinforcement operation trolley. The automatic sleeper dispersing device on the mobile operation trolley is used to lay the sleepers at intervals on the assembly platform. N2: Rail panel installation: The prefabricated modular rail frame is hoisted onto the sleeper using a rail frame transfer trolley, and the rail frame is roughly adjusted so that its position relative to the sleeper meets the construction standards. N3: Installation of formwork for track bed slab pouring: The upper-level casting formwork is installed on the outside of the upper-level steel reinforcement assembly using a formwork work trolley, and the plate-type track frame and the upper-level casting formwork are finely adjusted. N4: Casting and molding; The inner cavity enclosed by the upper casting formwork is filled with concrete, vibrated and finished. After molding, it is fully cured. After curing, the formwork is removed and the platen track frame is disassembled as a whole and transported to the next process.

2. The modular construction method for high-speed railway double-block ballastless track bed according to claim 1, characterized in that: The lower and upper steel reinforcement components adopt a mesh design, which consists of three sets of steel reinforcement mesh modules formed by the upper steel reinforcement mesh (9), the lower steel reinforcement mesh (10), and the edge-sealing frame steel reinforcement mesh (20). The three sets of steel reinforcement mesh modules are assembled and tied by a steel reinforcement work trolley, and the assembled steel reinforcement components are hoisted to the working beam surface using the hoisting equipment built into the steel reinforcement work trolley.

3. The modular construction method for high-speed railway double-block ballastless track bed according to claim 2, characterized in that: The assembly process of the steel reinforcement assembly is as follows: Step 1: Construction preparation; Step 2: Positioning of the moving bracket; Step 3: Hoisting of the lower steel reinforcement mesh (10); Step 4: Hoisting of the edge-sealing steel reinforcement mesh (20); Step 5: Hoisting of the upper steel reinforcement mesh (9); Step 6: Assembly of the steel reinforcement cage; Step 7: Hoisting of the steel reinforcement assembly. The specific assembly method is as follows: Positioning of the mobile bracket: The mobile bracket moves to the corresponding position in sequence according to the bracket support point position; Lower steel mesh (10) hoisting: The lower steel bars are hoisted to the mobile bracket using a special steel bar hoisting tool; (20) Lifting of edge-sealing steel mesh: The dual-degree-of-freedom control mechanism adjusts the position of the rotating bracket according to the elevation position of the upper steel bar and the support point of the upper steel bar, and lifts the erected steel bar; Upper steel mesh (9) hoisting: The upper steel bars are hoisted to the mobile bracket using special steel bar hoisting equipment; Rebar assembly: Rebar assembly is completed using robotic arms for hoisting and mobile binding / welding robots; Reinforcing bar assembly hoisting: hoisting to the beam surface using specialized reinforcing bar hoisting equipment.

4. The modular construction method for high-speed railway double-block ballastless track bed according to claim 3, characterized in that: The lower layer casting template includes the base plate casting template and the limiting groove template. After the limiting groove template is removed, the geotextile at that position is cut. Then, the cut geotextile is placed at the bottom of the formed limiting groove, and elastic gaskets are glued to the side of the limiting groove. The gaps between the glued areas are sealed with tape.

5. The modular construction method for high-speed railway double-block ballastless track bed according to claim 4, characterized in that: The upper casting template is a track bed slab casting template, and both the upper and lower casting templates are prefabricated templates (30) connected by magnetic attraction.

6. The modular construction method for high-speed railway double-block ballastless track bed according to claim 1, characterized in that: The plate-type track frame includes a main steel frame (2), which is used to simulate the track to be laid. The main steel frame (2) is installed on the double-block sleeper by steel pads.

7. The modular construction method for high-speed railway double-block ballastless track bed according to claim 6, characterized in that: Four sets of legs (1) fixed to the bridge deck are provided on the outside of the main steel frame (2). An adjustment assembly is provided between the legs (1) and the main steel frame (2). The adjustment assembly includes a longitudinal adjustment device (3) for adjusting the longitudinal position of the plate-type track frame and a lateral adjustment device (4) for adjusting the lateral position.

8. A modular construction method for high-speed railway double-block ballastless track bed according to claim 7, characterized in that: The slab track frame is equipped with measuring components for fine-tuning the sleeper grooves. The measuring components are set in four groups, and the four groups of measuring components are respectively set on the outside of the second sleeper and the penultimate sleeper in the double-block ballastless track construction section.

Images