Track freezing and gluing seamless construction process

Abstract

The invention discloses a rail freezing and gluing seamless construction technology. The technology comprises the following operation steps that S1, rust removal is conducted on the rail surface within the range of a steel rail clamping plate; s2, the ends of the steel rail joints are ground to be flat; s3, the joints of the two steel rails are aligned and tightly jacked; s4, steel rail freezing clamping plate rust removal; s5, the steel rail freezing clamping plate is glued; and S6, the steel rail joints are glued and formed. When the rail freezing gluing seamless construction technology is used, steel rails with derusted inner rail surfaces are placed on sleepers, the ends of joints of the two sets of steel rails are tightly attached to and abut against the sleepers, then the derusted surfaces of the two sets of steel rail clamping plates are coated with freezing glue, the two sets of steel rail clamping plates arranged in parallel are locked through butt-joint bolts and locking nuts, and the two sets of steel rail clamping plates are tightly attached to the sleepers. The two groups of steel rail joints are ensured to quickly realize seamless butt joint, and as the frozen adhesive is used for adhering the seamless joints, the joints are physically connected by using the adhesive, the internal parts of the joints cannot be damaged easily caused by welding, the frequent steel rail flaw detection is not needed, and the operation intensity and the working pressure of a flaw detection department can be greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of track splicing construction technology, specifically to a seamless track freezing and adhesive bonding construction process. Background Technology

[0002] Rail joints are weak points in railway and urban rail lines. Because of the gaps between the rail joints, the impact force on the track increases dramatically when a train passes over them, easily leading to joint defects. Currently, the main construction methods for eliminating rail joints in track maintenance include flash welding, gas pressure welding, and aluminothermic welding. On-site track maintenance primarily uses aluminothermic welding and gas pressure welding. By welding the rails, rail joints are eliminated, reducing track maintenance workload and improving train ride smoothness.

[0003] Currently, the construction process requires medium-sized welding machinery, a large number of personnel, long construction time, and high welding costs. Aluminothermic welding requires 6 personnel, each joint takes more than 120 minutes to weld, and the average cost is around 10,000 yuan. Gas pressure welding requires 20 personnel because it requires "bending" the track, each joint takes more than 110 minutes to weld, and the average cost is around 14,000 yuan.

[0004] Welding processes are complex, require high precision, and are prone to defects and damage. Aluminothermic welding and gas pressure welding require high precision, and construction personnel must undergo professional training and have sufficient trial welding experience before they can perform the work. Furthermore, complex type tests are required depending on the rail type, manufacturer, delivery condition, and the initial welding. Gas pressure welding, in particular, requires a one-to-one matching of personnel and machinery. If the construction personnel or machinery are changed, the type test must be repeated. Because of the complexity and high precision requirements of the welding process, welded joints are prone to defects and damage. Each welded joint requires ultrasonic testing, and handling defects and damage is extremely complicated. If damage occurs during on-line welding, it can potentially cause delays and affect train departure times.

[0005] In addition, rail welding easily leads to a large workload for later maintenance and repair. Because the welded joint has a different strength from the rail base material, it is prone to joint collapse and even fatigue damage during later operation. If the damage is not detected in time, it can easily lead to train derailment and safety accidents. In particular, the most commonly used aluminothermic welding is more prone to joint defects and damage. In order to eliminate the welded joint, it is necessary to cut off the weld and the rail within a certain length around it, and then re-weld, making the construction operation extremely complicated and cumbersome.

[0006] Meanwhile, existing technologies such as aluminothermic welding and gas pressure welding are both hot work operations, requiring the rails to be heated to a certain temperature before welding can be performed. Welding is inconvenient when the temperature at the construction site is below zero, which makes rail welding operations impossible in winter.

[0007] Therefore, we proposed a seamless track freezing and bonding construction process. Summary of the Invention

[0008] The purpose of this invention is to provide a seamless construction process for track freezing adhesive bonding to solve the problems mentioned in the background art.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a seamless track freezing and bonding construction process, comprising the following operational steps:

[0010] S1: Rust removal from the rail surface within the rail clamp area;

[0011] S2: The ends of the rail joints are ground flat;

[0012] S3: The two rail joints are aligned and locked in place;

[0013] S4: Rust removal from frozen rail clamps;

[0014] S5: Apply adhesive to frozen rail clamps;

[0015] S6: Rail joints are glued and molded.

[0016] Preferably, the bottom of the rail is placed on the sleeper, and the sleeper is clamped to the extended surface of the bottom of the rail by matching anti-loosening fasteners. Before the rust removal step is performed on the rail surface within the rail clamping plate area, the anti-loosening fasteners on the sleeper are removed, and the two sets of rail joints are placed in a staggered manner.

[0017] Preferably, the rust removal of the rail surface within the rail clamp range in step S1 is performed by a rail grinding machine on the inner rail surfaces on both sides of the rail. The rail grinding machine drives the grinding wheel to rotate and the working surface of the grinding wheel is placed against the inner rail surface of the rail. The reciprocating movement of the rail grinding machine drives the grinding wheel to remove dirt and rust from the inner rail surface of the rail joint.

[0018] Preferably, in step S2, the end grinding of the rail joints is performed by using a rail grinding machine that has completed rust removal to grind the ends of the two sets of rail joints.

[0019] Preferably, the step of aligning and locking the two rail joints requires aligning the ends of the two sets of rail joints that have been ground flat to prevent misalignment, and pressing the two sets of rail joints together tightly by a bidirectional hydraulic rail gap adjuster.

[0020] Preferably, in step S4, the rust removal of the frozen rail clamps involves using the rail grinding machine to remove dirt and rust from the surface of the rail clamps near the rail joints, and cleaning the impurities removed by grinding the surface of the rail clamps.

[0021] Preferably, the adhesive application to the frozen rail clamps in step S5 includes the following steps:

[0022] S51: Apply the freezing adhesive in a straight line to the rust-removed surface of the rail clamp with multiple adhesive lines;

[0023] S52: Smooth out multiple straight adhesive lines and ensure that the adhesive covers the entire surface of the bonding side of the frozen clamp.

[0024] Preferably, in step S6, the rail joint adhesive molding requires that the rail clamps coated with freezing adhesive be tightly aligned with the sides of the two sets of rail joints, and that the bolt holes of the freezing clamps be aligned with the rail holes.

[0025] Preferably, after aligning the bolt holes of the freezing clamp with the rail holes, insert the butt bolts and lock nuts, and tighten the butt bolts to a torque of 900-1100 N*M by repeatedly tightening the force.

[0026] Preferably, there are six connecting bolts and six locking nuts, and the six connecting bolts are arranged alternately when passing through two sets of rail joints and two sets of rail clamps.

[0027] Compared with the prior art, the beneficial effects of the present invention are:

[0028] 1. When using this seamless rail bonding process with frozen adhesive, the rails with rust removed from the inner rail surface are placed on the sleepers, and the ends of the two sets of rail joints are tightly pressed together. Then, frozen adhesive is applied to the rust-removed surfaces of the two sets of rail clamps. The two sets of parallel rail clamps are locked with butt bolts and lock nuts to ensure that the two sets of rail joints can be quickly and seamlessly connected. Since the seamless joint is bonded by frozen adhesive, the joint will not have the damage that is easy to occur when welding. Frequent rail flaw detection inspection is not required, which can greatly reduce the workload and pressure of the flaw detection department.

[0029] 2. This seamless track freezing and bonding construction process is not limited by the rail manufacturer or the rail material, and does not require type testing. Rails of the same model can be glued and frozen into shape. As train operation and traffic increase, when the adhesive fails and the joint becomes loose, the rail clamps can be removed, allowing the rails to be re-bonded in the original position after rust removal and grinding. This reduces the workload of maintenance and repair. Compared with welding construction process, freezing and bonding construction process can reduce joint defects equally.

[0030] 3. The seamless track freezing and bonding construction process is suitable for track switches because existing rail transit switches generally have a certain number of live joints. This is because switch rail components are prone to damage and often need to be replaced. If welding is used for replacement, the construction process is relatively complicated. Through the seamless track freezing and bonding construction, the frozen adhesive forms a seamless joint. When replacing rail components, the joint can be quickly disassembled using tooling and re-bonded in situ, which is convenient and fast. Therefore, this process is suitable for joints in switch areas to form frozen adhesive joints. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the process flow structure of the present invention;

[0032] Figure 2 This is a three-dimensional structural diagram of the present invention;

[0033] Figure 3 This is a schematic diagram of the adhesive application on the rail clamps of the present invention.

[0034] In the diagram: 1. Rail joint No. 1; 2. Rail joint No. 2; 3. Rail clamp; 4. Butt bolt; 5. Locking nut; 6. Sleeper; 7. Anti-loosening fastener. Detailed Implementation

[0035] 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.

[0036] Please see Figure 1 This invention provides a technical solution: a seamless track freezing and bonding construction process, comprising the following steps:

[0037] S1: Rust removal of the rail surface within the rail clamp area involves placing the bottom of the rail on the sleeper, with the sleeper clamping the extended surface of the rail bottom using matching anti-loosening fasteners. Before removing rust from the rail surface within the rail clamp area, the anti-loosening fasteners on the sleeper are removed, and the two sets of rail joints are placed in a staggered manner. Rust removal of the rail surface within the rail clamp area is performed by using a rail grinding machine to remove rust from the inner rail surfaces on both sides of the rail. The rail grinding machine drives the grinding wheel to rotate, and the working surface of the grinding wheel is placed against the inner rail surface of the rail. The reciprocating movement of the rail grinding machine drives the grinding wheel to remove dirt and rust from the inner rail surface of the rail joint.

[0038] When performing rust removal operations on the rail surface within the rail clamp area, the rail grinding machine is oscillated according to the structure of the inner rail surface to achieve thorough polishing and rust removal of the inner rail surface.

[0039] S2: The ends of the rail joints are ground flat. The ends of the two sets of rail joints are ground flat using a rail grinding machine that has completed the rust removal operation.

[0040] S3: Align and tighten the two rail joints. The process of aligning and tightening the two rail joints requires aligning the ends of the two sets of rail joints that have been ground flat to prevent misalignment, and then pressing the two sets of rail joints together tightly by using a two-way hydraulic rail gap adjuster.

[0041] S4: Rust removal from frozen rail clamps. The rail clamps are rusted by using the rail grinding machine to remove dirt and rust from the surface of the rail clamps near the rail joints, and to clean the impurities removed by grinding the surface of the rail clamps.

[0042] S5: Apply adhesive to frozen rail clamps;

[0043] See Figure 3 It can be seen that the adhesive application process for frozen rail clamps includes the following steps: First, apply the freezing adhesive in straight lines along multiple adhesive lines on the rust-removed surface of the rail clamp 3; then, smooth out the multiple straight adhesive lines, ensuring that the adhesive covers the entire bonding surface of the frozen clamp. This comprehensive adhesive coverage ensures that the adhesive is evenly distributed across the bonding area during the pressing and spreading process, guaranteeing uniform bonding.

[0044] S6: Rail joint adhesive molding. For rail joint adhesive molding, the rail clamp plate 3 with the applied freezing adhesive is tightly aligned with the sides of the two sets of rail joints, and the bolt holes of the freezing clamp plate are aligned with the rail holes. After the bolt holes of the freezing clamp plate are aligned with the rail holes, the butt bolts 4 and lock nuts 5 are inserted. By repeatedly tightening and applying force, the butt bolts 4 are tightened to a torque of 900-1100 N*M. There are six butt bolts 4 and six lock nuts 5. The six butt bolts 4 are arranged alternately when passing through the two sets of rail joints and the two sets of rail clamp plates 3. The first, third and fifth butt bolts 4 are inserted from right to left, and the second, fourth and sixth butt bolts 4 are inserted from left to right, so as to ensure the stability of locking.

[0045] By adopting the above construction process, the frozen adhesive seamless joint is more economical, and the rail clamp 3 of the frozen seamless joint can be recycled and reused, thereby reducing waste. By using this track frozen adhesive seamless construction process, the cost of forming a joint is less than 4,000 yuan, with significant economic benefits. Each seamless joint can reduce costs by more than 60% compared to welding.

[0046] For specific implementation, please refer to Figure 2It is known that during the seamless construction of track freezing adhesive, the steel rails with rust removed from the inner rail surface are placed on the sleeper 6, and the ends of the ground No. 1 rail joint 1 and No. 2 rail joint 2 are tightly pressed together using tools. Then, the freezing adhesive of the specified line shape is applied to the rust-removed surface of the two sets of rail clamps 3. The two sets of rail clamps 3 are connected to the two sides of No. 1 rail joint 1 and No. 2 rail joint 2, and the two sets of parallel rail clamps 3 are locked with connecting bolts 4 and locking nuts 5 to ensure that No. 1 rail joint 1 and No. 2 rail joint 2 can be quickly and seamlessly connected.

[0047] By using frozen adhesive to bond seamless joints, the physical connection is achieved through bonding. This prevents damage that is common in welding from occurring inside the joint, eliminating the need for frequent rail flaw detection inspections. This significantly reduces the workload and stress on the flaw detection department. On-site operation is simple and construction is quick and easy. On-site work mainly involves grinding and rust removal. The process is simple, construction can be carried out quickly, and the labor intensity is low. Each joint can be completed in 30 minutes, reducing labor intensity and maintenance workload.

[0048] The most temperature-dependent aspect of this construction process is the curing of the adhesive. When the temperature is low, the adhesive does not easily solidify. This can be addressed by using a simple heat insulation cover to cover the frozen joint and then heating it, thus minimizing the impact of temperature on the construction process.

[0049] In summary, during the seamless construction of frozen and bonded rails, rust is removed from the rail surface within the rail clamp area, and the ends of the rail joints are ground flat. After grinding, tools are used to align and clamp the two rail joints to achieve a seamless connection. Then, the rail clamps are derusted. After derusting, adhesive is applied to the rail clamps, so that the adhesive-coated rail clamps 3 can clamp and limit the two sets of rail joints and ensure their use after adhesive bonding. By installing anti-loosening fasteners 7 on the sleepers 6, the anti-loosening fasteners 7 can lock and prevent the rails from loosening, ensuring that the track constructed by frozen and bonded seamless construction has a rapid splicing effect. The contents not described in detail in this specification are existing technologies known to those skilled in the art.

[0050] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A seamless track freezing and adhesive bonding construction process, characterized in that, The following steps are included: S1: Rust removal from the rail surface within the rail clamp area; S2: The ends of the rail joints are ground flat; S3: The two rail joints are aligned and locked in place; S4: Rust removal from frozen rail clamps; S5: Apply adhesive to frozen rail clamps; S6: Rail joints are glued and molded.

2. The seamless track freezing and bonding construction process according to claim 1, characterized in that: The bottom of the rail is placed on the sleeper, and the sleeper is clamped to the extended surface of the bottom of the rail by matching anti-loosening fasteners. Before the rust removal step is carried out on the rail surface within the rail clamp area, the anti-loosening fasteners on the sleeper are removed, and the two sets of rail joints are placed in a staggered manner.

3. The seamless track freezing and bonding construction process according to claim 1, characterized in that: The rust removal of the rail surface within the rail clamp area mentioned in step S1 is carried out by a rail grinding machine to remove rust from the inner rail surfaces on both sides of the rail. The rail grinding machine drives the grinding wheel to rotate and the working surface of the grinding wheel is placed against the inner rail surface of the rail. The reciprocating movement of the rail grinding machine drives the grinding wheel to remove dirt and rust from the inner rail surface of the rail joint.

4. The seamless track freezing and bonding construction process according to claim 1, characterized in that: The end grinding of the rail joints in step S2 is performed by using a rail grinding machine that has completed the rust removal operation to grind the ends of the two sets of rail joints.

5. The seamless track freezing and bonding construction process according to claim 1, characterized in that: The step of aligning and locking the two rail joints requires aligning the ends of the two sets of rail joints that have been ground flat to prevent misalignment, and then pressing and locking the two sets of rail joints together tightly using a bidirectional hydraulic rail gap adjuster.

6. The seamless track freezing and bonding construction process according to claim 1, characterized in that: Step S4 involves removing rust from the frozen rail clamps by using the rail grinding machine to clean the surface of the rail clamps near the rail joints, and to remove the impurities removed by grinding the surface of the rail clamps.

7. The seamless track freezing and bonding construction process according to claim 1, characterized in that: Step S5, which involves applying adhesive to the frozen rail clamps, includes the following steps: S51: Apply the freezing adhesive in a straight line to the rust-removed surface of the rail clamp with multiple adhesive lines; S52: Smooth out multiple straight adhesive lines and ensure that the adhesive covers the entire surface of the bonding side of the frozen clamp.

8. The seamless track freezing and bonding construction process according to claim 1, characterized in that: The rail joint bonding molding process described in step S6 requires that the rail clamps coated with freezing adhesive be tightly attached and aligned to the sides of the two sets of rail joints, and that the bolt holes of the freezing clamps be aligned with the rail holes.

9. The seamless track freezing and bonding construction process according to claim 8, characterized in that: After aligning the bolt holes of the freezing clamp with the rail holes, insert the butt bolts and lock nuts, and tighten the butt bolts to a torque of 900-1100 N*M by repeatedly tightening the force.

10. The seamless track freezing and bonding construction process according to claim 9, characterized in that: There are six connecting bolts and six locking nuts, and the six connecting bolts are arranged alternately when passing through two sets of rail joints and two sets of rail clamps.

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