Railway ballastless track filling layer rope saw cutting device and repairing method

Abstract

This invention discloses a wire saw cutting device and repair method for the filling layer of ballastless railway track, belonging to the field of railway maintenance technology. The device includes a track traveling device symmetrically arranged on both sides of the track structure, and a wire saw cutting device consisting of an active unit and a driven unit mounted on it. Both the active and driven cutting units are equipped with height-adjustable directional wheels. A diamond rope winds around each directional wheel, forming two cutting rope segments below the track bed slab, which are connected end-to-end to form a closed loop. The directional wheels on both sides are configured at different heights, creating a height difference between the upper and lower rope segments in the lateral direction, thereby cutting a block in one operation. This invention places the wire saw device in a working groove below the track bed slab. When the rope breaks, the rope only swings downwards or horizontally and is blocked by the working groove, eliminating the safety hazards of injury to people and damage to track equipment. The cut block is easy to remove, the tension of the upper and lower ropes is consistent throughout the entire process, resulting in high cutting efficiency and significantly saving track maintenance time.

Description

Technical Field

[0001] This invention belongs to the field of railway ballastless track repair technology, and particularly relates to a wire saw cutting device and repair method for railway ballastless track filling layer. Background Technology

[0002] After years of operation, the infill or support layer beneath the ballastless track slab of railways can develop defects due to various geological and load-bearing factors, such as arching, settlement, or mud pumping. These problems directly lead to track unevenness and affect train operation safety. Thorough repair often requires cutting away the damaged infill or support layer concrete and then re-pouring it. However, this work has a major challenge: it can only be carried out during very short "track maintenance windows" at night, and it is absolutely crucial to avoid damaging the track structure itself, and to prevent flying debris or broken equipment from endangering on-site personnel and equipment. Therefore, how to cut it and what material to use for cutting it become major problems.

[0003] Currently, there are some explorations of cutting equipment and methods in the industry, but they all have obvious shortcomings.

[0004] For example, one type of equipment is the wire saw cutting machine. For instance, existing technology discloses a device for cutting mortar layers using a diamond wire saw, publication number CN203807901U. It uses a diamond wire saw to horizontally cut the mortar layer by passing under the track slab. However, this equipment is placed above the track, using a cross-track arrangement, resulting in a very long diamond wire saw cable. In the tense working environment of track maintenance windows where every second counts, the long cable vibrates significantly during operation. If the tension is not properly controlled and the cable breaks, the enormous energy stored in the cable will be released instantly, with a very large impact range, easily injuring people and track equipment, posing a high safety risk. Moreover, it can only cut one side at a time; to remove a complete block, it must be cut repeatedly several times (e.g., ...). Figure 10 Not only is it inefficient, but the cut pieces are also irregularly shaped and difficult to remove smoothly from under the track.

[0005] Another type of equipment uses chainsaws. For example, existing technology discloses a railway subgrade fill cutting and replacement construction device and method, with publication number CN115125772A. The chainsaw bracket is placed on the support layer on both sides of the track, with the chainsaw itself spanning under the track slab. It cuts the subgrade horizontally by traction. While this method places the equipment on both sides of the track, solving the safety problem of long wire saws, its chainsaw structure can only cut a single horizontal slit of uniform thickness. Its initial purpose is to cut a slit in the subgrade fill to facilitate subsequent grouting or correction, not to remove and replace the entire fill piece. Even if one wanted to cut a whole piece, multiple cuts are required, still facing the old problems of cutting irregular blocks, difficulty in removal, and low work efficiency.

[0006] Therefore, the market urgently needs a cutting solution that can simultaneously ensure safety and efficiency—it must be able to quickly complete the operation using the skylight, firmly control the risk of rope breakage, and cut out a regular-shaped block that can be easily pulled out from under the track in one go. Summary of the Invention

[0007] To address the problems existing in the prior art, this invention provides a wire saw cutting device and repair method for the filling layer of railway ballastless track, in order to solve the two major problems of existing wire saw equipment being unable to simultaneously achieve "safe operation with short ropes" and "efficient one-time cutting" in ballastless track maintenance.

[0008] This invention is implemented as follows: a wire saw cutting device for the filling layer of ballastless railway track, used to cut the filling layer or support layer under the track slab. It is characterized by comprising: a track traveling device symmetrically arranged on both sides of the ballastless track structure; a wire saw cutting device divided into an active cutting unit and a driven cutting unit, respectively installed on the track traveling device on both sides of the track structure; the active cutting unit and the driven cutting unit each include a height-adjustable main directional wheel and a height-adjustable secondary directional wheel, with diamond wire wound around the height-adjustable main directional wheel and the height-adjustable secondary directional wheel on the active cutting unit and the driven cutting unit, forming two cutting rope segments below the track slab, which are connected end-to-end to form a closed loop; the track traveling device is used to drive the active cutting unit and the driven cutting unit to move synchronously along the track direction; the height-adjustable main directional wheel and the height-adjustable secondary directional wheel located on both sides of the track structure are configured with different heights, so that there is a lateral height difference between the upper and lower cutting rope segments, thereby cutting a block in one go.

[0009] In a further preferred embodiment, the wire saw travel track is fixed to both sides of the ballastless track structure along the line direction, with a rack on the outer side of its middle section; the travel bracket is movably mounted on the wire saw travel track via track guide wheels, and a support wheel is also provided below the travel bracket to contact the wire saw travel track; the travel drive unit is fixed to the travel bracket, and its output end is provided with a gear that meshes with the rack, for providing power for the travel bracket to travel along the line direction.

[0010] Further preferably, the active cutting unit installed on one side of the track structure includes: a main sawing power drive unit; a drive wheel driven by the main sawing power drive unit; a height-adjustable main directional wheel, which is installed below both ends of the walking bracket on this side through a directional wheel fixing seat, and the drive wheel is located between the two height-adjustable main directional wheels; the diamond rope is wound around the height-adjustable main directional wheel and the drive wheel.

[0011] Further preferably, the driven cutting unit installed on the other side of the track structure includes: a drive wheel bracket fixing base, fixed to the traveling bracket on that side; a drive wheel bracket, installed on the drive wheel bracket fixing base; a driven wheel, installed on the drive wheel bracket; a height-adjustable driven wheel, installed below both ends of the traveling bracket on that side via a driven wheel fixing seat, the driven wheel being located between the two height-adjustable driven wheels; and a diamond rope wound around the height-adjustable driven wheel and the driven wheel.

[0012] More preferably, the active cutting unit further includes a direction adjustment turntable for fixing the main sawing power drive unit. The direction adjustment turntable is fixed on the walking bracket and is used to adjust the installation angle of the main sawing power drive unit and the drive wheel.

[0013] More preferably, the height-adjusting main guide wheel and the height-adjusting secondary guide wheel adjust their own height by changing their installation position on the guide wheel fixing seat, so that the height difference between the upper and lower cutting rope segments is adjustable within the range of 0-30cm.

[0014] More preferably, the wire saw cutting device further includes a drive wheel protective cover and a directional wheel protective cover, which are respectively installed on the outside of the drive wheel and the height-adjusting main directional wheel and the height-adjusting secondary directional wheel, to limit the impact range of the diamond wire to the working grooves on both sides of the track structure when the diamond wire breaks accidentally.

[0015] More preferably, both the active cutting unit and the driven cutting unit include cooling nozzles that travel together with the active cutting unit and the driven cutting unit, and the cooling nozzles are connected to the coolant supply unit through pipelines.

[0016] Further preferably, the driven cutting unit is also provided with an auxiliary sawing power drive unit, which is connected to the driven wheel. When dual-side power drive is required, the auxiliary sawing power drive unit drives the diamond rope synchronously with the main sawing power drive unit of the active cutting unit, so as to be suitable for turnout areas or high cutting resistance conditions.

[0017] The present invention also relates to a method for repairing the filling layer of railway ballastless track, which uses the above-mentioned wire saw cutting equipment for the filling layer of railway ballastless track, including the following steps: S1: symmetrically install track walking devices on both sides of the track structure, fix the wire saw walking track along the line direction to both sides of the track structure, and install the walking bracket with the wire saw cutting device on the wire saw walking track.

[0018] S2: Pass the diamond rope through the hole pre-drilled in the track structure and wind it according to the configuration relationship of the active cutting unit and the driven cutting unit. After connecting the ends, the diamond rope is tensioned by moving the traveling bracket on one side.

[0019] S3: Adjust the height of the height adjustment directional wheels on the wire saw cutting devices located on both sides of the track structure so that the height difference between the upper and lower cutting rope segments formed by the diamond rope below the track bed is the required value. The height difference can be set to zero or non-zero to cut out square blocks or wedge-shaped blocks respectively.

[0020] S4: Start the main sawing power drive unit on the active cutting unit to drive the diamond rope to rotate, and simultaneously start the walking drive unit to drive the walking bracket to move along the line direction, so as to cut into cutting blocks in one go;

[0021] When the working section is a turnout area or the cutting resistance exceeds a preset threshold, the auxiliary sawing power drive unit on the driven cutting unit is activated simultaneously, so that the auxiliary sawing power drive unit and the main sawing power drive unit drive the diamond rope synchronously to achieve dual-side power coordinated cutting.

[0022] S5: Remove the cut blocks formed by cutting and provide temporary support for the track structure;

[0023] S6: Adjust the track structure after removing the cut blocks, erect the mold, and inject new filling material for repair.

[0024] The advantages and technical effects of this invention are as follows:

[0025] Compared with the prior art, the present invention mainly achieves the following beneficial effects:

[0026] First, it ensures construction safety from the source. The equipment is placed in the working groove below the track bed slab, and with the full-coverage drive wheel guard and directional wheel guard, the impact space in the event of an accidental breakage of the diamond rope is firmly confined inside the working groove. The operator is in a safe area above the groove, completely eliminating the hidden dangers of rope breakage injury and damage to track equipment during high-speed wire sawing operations.

[0027] Secondly, it significantly improves the efficiency of skylight operation. The height adjustment main guide wheel and the height adjustment secondary guide wheel on both sides work together to create a height difference, allowing the upper and lower rope segments to cut out the cutting block in one go, eliminating the tedious steps of multiple cutting and chiseling in traditional processes; the cutting block has a built-in demolding slope, making it easy and quick to remove, effectively shortening the cutting and block removal time.

[0028] Third, the equipment is lightweight and modular in structure. The units are detachably connected, and the individual components are lightweight, making it easy for workers to quickly move up and down the track and disassemble and reassemble within the maintenance window, reducing auxiliary work time and shortening the length of the diamond rope.

[0029] Fourth, the cut surface is smooth and flat, causing almost no secondary damage to the surrounding existing structure. This facilitates the pouring and interface bonding of subsequent new filling materials, ensuring the long-term quality of the remediation and repair. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0031] Figure 2 This is a schematic diagram of the active cutting unit structure;

[0032] Figure 2a This is a schematic diagram of an eccentric shaft structure;

[0033] Figure 2b yes Figure 2a The left view;

[0034] Figure 3 yes Figure 2 Top view;

[0035] Figure 4 yes Figure 2 The right view;

[0036] Figure 5 This is a schematic diagram of the active cutting unit structure;

[0037] Figure 6 yes Figure 5 Top view; Figure 7 yes Figure 5 The left view;

[0038] Figure 8 This is a schematic diagram of the assembly structure of the direction adjustment turntable and the drive unit mounting base;

[0039] Figure 9 yes Figure 8 Sectional view of AA;

[0040] Figure 10 These are diagrams showing the positions of the first and second cuts using a traditional wire saw cutting device.

[0041] Figure 11 This is a diagram showing the length arrangement of the diamond wire in a traditional wire saw cutting device.

[0042] Figure 12 This is a diagram showing the length arrangement of the diamond cord of the present invention;

[0043] Figure 13This is a schematic diagram of the dual-sided sawing power drive unit structure.

[0044] In the diagram: 11. Track travel device; 12. Wire saw travel track; 121. Rack; 13. Travel support; 14. Track guide wheel; 15. Eccentric shaft; 151. Locking nut; 152. Key; 153. Force application lug; 16. Support wheel; 17. Travel drive unit; 171. Gear; 21. Wire saw cutting device; 210. Active cutting unit; 220. Driven cutting unit; 221. Auxiliary sawing power drive unit.

[0045] 22. Main sawing power drive unit; 23. Gearbox; 24. Drive wheel; 25. Directional wheel mounting base; 261. Height-adjustable main directional wheel; 262. Height-adjustable secondary directional wheel; 263. Directional wheel connecting rod; 27. Direction adjustment turntable; 31. Drive wheel bracket mounting base; 32. Drive wheel bracket; 33. Secondary drive wheel; 40. Diamond rope; 51. Drive wheel protective cover; 52. Directional wheel protective cover; 60. Cooling device. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0047] This embodiment provides a wire saw cutting device for the filling layer of railway ballastless track, used to cut the filling layer or support layer below the track bed slab.

[0048] like Figures 1 to 7 As shown, the equipment mainly consists of two parts: a track-walking device 11 and a wire saw cutting device 21. The track-walking device 11 is symmetrically arranged on both sides of the ballastless track structure. The wire saw cutting device 21 is divided into an active cutting unit and a driven cutting unit, which are respectively installed on the track-walking device 11 on both sides of the track structure. The active cutting unit and the driven cutting unit each include a height-adjusting main guide wheel 261 and a height-adjusting driven guide wheel 262. The diamond rope 40 winds around the height-adjusting main guide wheel 261 and height-adjusting driven guide wheel 262 on the active cutting unit and the driven cutting unit, forming two cutting rope segments below the track bed slab, which are connected end to end to form a closed loop. The diamond rope 40 is made of sintered diamond beads, resulting in high cutting efficiency and long service life. The length of the diamond rope 40 is significantly reduced compared to traditional methods. Please refer to [link / reference]. Figure 11 and Figure 12The track-walking device 11 is used to drive the active cutting unit and the driven cutting unit to move synchronously along the track direction. The height-adjusting main guide wheel 261 and the height-adjusting secondary guide wheel 262 located on both sides of the track structure are configured to have different heights so that there is a lateral height difference between the upper and lower cutting rope segments, thereby cutting out the cutting block in one go.

[0049] The core concept of the above technical solution is to lower the entire wire saw cutting equipment from its traditional placement above or across the track into a working groove beneath the track bed slab on both sides. The cutting block is then cut in one go using the height difference between the guide wheels on both sides. Its working principle and technical advantages are as follows: In terms of safety, the equipment is positioned in the working groove beneath the track bed slab. The diamond wire has a short and controllable path. In the event of an accidental wire breakage, the broken wire will only swing downwards or horizontally, directly blocked by the side walls and bottom of the working groove. The operator is in a safe area above the working groove, fundamentally eliminating the hidden dangers of rope breakage and injury to personnel and damage to track equipment associated with traditional cross-track wire saws. In terms of efficiency, the height adjustment main guide wheel and the height adjustment slave guide wheel on both sides are set at different heights, so that the upper and lower cutting rope segments formed by the diamond rope under the track bed are parallel in the lateral direction or have a certain height difference, that is, a gradual height difference with a large cutting height at one end and a small cutting height at the other end. A single pass of the cutter can cut out a cutting block with non-parallel upper and lower surfaces. The cutting block has a built-in demolding slope, which makes it very convenient to remove, greatly shortening the operation time within the track window.

[0050] The components are described in further detail below.

[0051] The track-walking device 11 includes a wire saw track 12, a walking support 13, track guide wheels 14, support wheels 16, and a walking drive unit 17. The wire saw track 12 is fixed to both sides of the ballastless track structure along the track direction, and a rack 121 is provided on the outer side of its middle part; the walking support 13 has a frame structure and is movably installed on the wire saw track 12 through the track guide wheels 14.

[0052] Specifically, please refer to Figure 2a and Figure 2bThe track guide wheel 14 is fixed to the upper two ends and the lower two ends of the traveling bracket 13 by the eccentric shaft 15. The track guide wheel 14 is placed on the upper guide rail and the lower guide rail of the wire saw traveling track 12 and can move along the upper guide rail of the wire saw traveling track 12. One end of the eccentric shaft 15 is a threaded connection end and the other end is a smooth shaft end. The threaded connection end passes through the side of the traveling bracket, and its end is sequentially equipped with a key 152, a force-applying ear plate 153, and a locking nut 151. The key 152 cooperates with the keyway on the eccentric shaft 15 and the force-applying ear plate 153 to realize torque transmission. After the locking nut 151 is loosened, it is used to rotate the eccentric shaft to make the track guide wheel leave the upper guide rail, thereby realizing the disassembly of the entire track traveling device 11.

[0053] Below the traveling support 13, there is a support wheel 16 that contacts the wire saw traveling track 12. The traveling drive unit 17 is fixed to the traveling support 13, and its output end is provided with a gear 171 that meshes with the rack 121, which is used to provide power for the traveling support 13 to travel along the track direction. The traveling drive unit 17 can be a permanent magnet motor, a pneumatic motor or a hydraulic power source, and can also provide traveling power for the traveling support 13 on the wire saw traveling track 12 by traction.

[0054] The working principle and technical effect of the aforementioned track-walking device 11 are as follows: The wire saw walking track 12 is firmly fixed to the side of the track structure by expansion bolts, providing a rigid operating reference for the entire equipment. The gear 171 at the output end of the walking drive unit 17 meshes with the rack 121 on the track, driving the walking bracket 13 forward through gear and rack transmission. This mechanical transmission method has good synchronization, and the walking speed on both sides can maintain a high degree of consistency, without slippage, ensuring the flatness of the cutting surface. At the same time, the track guide wheel 14 is engaged with the upper and lower guide rails of the wire saw walking track 12, and the support wheel 16 is supported by the side of the track below. The three points work together to stably constrain the walking bracket 13 on the track, and the equipment will not jump or deviate when the cutting resistance changes.

[0055] like Figures 2 to 4 As shown, the active cutting unit 210 installed on one side of the track structure includes a main sawing power drive unit 22, a gearbox 23, a drive wheel 24, a directional wheel fixing seat 25, and a height-adjustable main directional wheel 261. The main sawing power drive unit 22 is connected to the drive wheel 24 via the gearbox 23, and the drive wheel 24 is driven by the main sawing power drive unit 22. The height-adjustable main directional wheel 261 is connected to the directional wheel fixing seat 25 via a directional wheel connecting rod 263 and is installed below both ends of the traveling bracket 13 on this side. The drive wheel 24 is located between the two height-adjustable main directional wheels 261. The diamond rope 40 is wound around the height-adjustable main directional wheel 261 and the drive wheel 24. The main sawing power drive unit 22 can be a permanent magnet motor, a pneumatic motor, or a hydraulic power unit.

[0056] The working principle and technical effect of the aforementioned active cutting unit are as follows: the torque output by the main sawing power drive unit 22 is reduced and amplified by the gearbox 23 and then transmitted to the drive wheel 24. The drive wheel 24 drives the diamond rope 40 to rotate at high speed by friction, thereby achieving grinding and cutting of the concrete or mortar layer. Two height-adjustable main directional wheels 261 are located on the left and right sides below the drive wheel 24, respectively. Adjusting the relative height of the two height-adjustable main directional wheels 261 changes the direction of the diamond rope 40, ensuring that the rope enters and leaves the cutting area at the correct angle and height after exiting the drive wheel 24. This layout makes the active side structure compact, the power transmission path short, and the energy loss small. The installation height of the directional wheels can be flexibly adjusted through the directional wheel fixing seat 25.

[0057] like Figures 5 to 7 As shown, the driven cutting unit 220 installed on the other side of the track structure includes a drive wheel bracket fixing base 31, a drive wheel bracket 32, a driven drive wheel 33, a directional wheel fixing seat 25, and a height-adjustable driven directional wheel 262. The drive wheel bracket fixing base 31 is fixed to the traveling bracket 13 on this side; the drive wheel bracket 32 ​​is installed on the drive wheel bracket fixing base 31, and the angle of the driven drive wheel 33 can be adjusted by rotating the drive wheel bracket 32; the driven drive wheel 33 is installed on the drive wheel bracket 32; the height-adjustable driven directional wheel 262 is connected to the directional wheel fixing seat 25 through the directional wheel connecting rod 263, and is installed below both ends of the traveling bracket 13 on this side, with the driven drive wheel 33 located between the two height-adjustable driven directional wheels 262; the diamond rope 40 is wound around the height-adjustable driven directional wheel 262 and the driven drive wheel 33.

[0058] The working principle and technical effect of the aforementioned driven cutting unit are as follows: the driven cutting unit mainly plays the role of following and tensioning, and does not actively provide power itself, but its structural design ensures that the tension of the diamond rope 40 is uniform and adjustable. The drive wheel bracket 32 ​​is mounted on the drive wheel bracket fixed base 31. By rotating the drive wheel bracket 32, the angle of the driven wheel 33 can be finely adjusted, which is particularly useful when installing the diamond rope 40 or adjusting the rope tension. After the main sawing power drive unit 22 is started, the diamond rope 40 circulates between the active unit and the driven unit. The directional wheel fixed bases 25 on both sides, as well as the height-adjusting main directional wheel 261 and the height-adjusting driven directional wheel 262, cooperate with each other to ensure that the diamond rope 40 is under effective guidance and support throughout the process, preventing it from deviating or loosening. Depending on the amount of power required for cutting, the wire saw cutting device 21 can be configured with the main sawing power drive unit 22 on one side or on both sides simultaneously.

[0059] The active cutting unit also includes a direction adjustment turntable 27 for fixing the main sawing power drive unit 22. The direction adjustment turntable 27 is fixed on the traveling bracket 13 and is used to adjust the installation angle of the main sawing power drive unit 22 and the drive wheel 24. For specific structure, see the figure. The inner hole of the direction adjustment turntable 27 is press-fitted with a drive unit fixing seat 221, which is fixedly connected to the main sawing power drive unit 22. The function of the direction adjustment turntable 27 is that, at the construction site, due to slight differences in the dimensions of the track structure or slight changes in the length of the diamond rope 40 after wear, the rope may experience uneven wear or uneven stress. In this case, loosening the locking bolt of the direction adjustment turntable 27, rotating it slightly at a certain angle, and then locking it again can restore the rope to its optimal operating state. The operation is simple and quick.

[0060] The height-adjustable main guide wheel 261 and the height-adjustable secondary guide wheel 262 adjust their height by changing their installation position on the guide wheel fixing seat 25, thus making the height difference between the upper and lower cutting rope segments adjustable within the range of 0 to 30 cm. During construction, depending on the size of the cutting block required on site, the height-adjustable main guide wheel 261 and the height-adjustable secondary guide wheel 262 are adjusted to different extension lengths. After the diamond rope 40 is wound, the upper and lower cutting rope segments naturally form a height difference, and this height difference gradually changes from one side of the track to the other, thereby cutting a wedge-shaped surface. The adjustment range of 0 to 30 cm covers the thickness requirements of common filling and support layers.

[0061] Further preferably, the wire saw cutting device 21 also includes a drive wheel protective cover 51 and a guide wheel protective cover 52. The drive wheel protective cover 51 covers the outside of the drive wheel, and the guide wheel protective cover 52 covers the outside of the height-adjusting main guide wheel 261 and the height-adjusting secondary guide wheel 262. The drive wheel protective cover 51 and the guide wheel protective cover 52 are used to limit the impact range of the diamond rope 40 within the working grooves on both sides of the track structure in the event of an accidental breakage. The protective cover is the hardware guarantee for achieving intrinsic safety design. The drive wheel and each guide wheel are the key nodes for the high-speed rotation of the diamond rope 40, and also the locations where the risk of rope breakage is relatively concentrated. The protective cover completely covers these rotating parts, leaving only necessary openings in the direction of the diamond rope 40's entry and exit. Once the rope suddenly breaks during operation, the broken end is caught by the protective cover, and the rope can only swing within the confined space of the working groove. The kinetic energy is quickly absorbed by the groove wall and the cover, unlike traditional unsupported equipment that throws the broken rope several meters away, effectively protecting the operators and precision equipment such as electrical and communication systems on the track.

[0062] Both the active and passive cutting units include cooling nozzles that travel with them. These nozzles are connected to a coolant supply unit via piping. Cutting concrete with the diamond wire 40 involves a combination of dry grinding and cutting, generating significant heat. The cooling nozzles spray cooling water directly onto the diamond wire 40 as it enters the cutting area. This removes frictional heat, protecting the integrity of both the diamond wire 40 and the cut concrete surface. Furthermore, the water flow wets and settles the fine dust generated during cutting, preventing dust from contaminating the contact wire insulators and signal equipment. The nozzles' movement with the unit ensures precise cooling positioning at all times, eliminating the need for manual hand-held operation.

[0063] In another embodiment, please refer to Figure 13 Considering the asymmetry of the track structure in the turnout area and the insufficient driving force on one side under high cutting resistance conditions, the driven cutting unit is also equipped with an auxiliary sawing power drive unit 221. This auxiliary sawing power drive unit 221 is connected to the driven wheel 33 to provide active driving force to the driven cutting unit. When dual-sided power drive is required, the auxiliary sawing power drive unit 221 operates synchronously with the main sawing power drive unit 22 of the active cutting unit, jointly driving the diamond rope 40. This effectively increases the total driving torque of the system, ensuring the diamond rope maintains a stable linear velocity under high resistance conditions, while avoiding overload of the single-sided drive unit. This significantly improves the equipment's adaptability and operational reliability in turnout areas and complex cutting conditions.

[0064] The auxiliary sawing power drive unit 221 can be flexibly configured according to actual working conditions. Specifically, the auxiliary sawing power drive unit 221 can be used as an optional component, temporarily installed on the driven cutting unit in special working conditions such as turnout areas or high cutting resistance, and put into use after being connected to the driven wheel 33; or it can be used as a standard component of the equipment, pre-fixed on the driven cutting unit, and in a non-working state (not started or disconnected from the power connection) under normal cutting conditions, and then started when dual-side power drive is required, operating synchronously with the main sawing power drive unit 22. Users can choose whether to activate the auxiliary sawing power drive unit 221 according to the on-site working environment, the magnitude of cutting resistance, and the equipment configuration. Both configuration methods can effectively improve the cutting capability of the equipment under complex working conditions, while taking into account the versatility and economy of the equipment.

[0065] This embodiment also provides a method for repairing the filling layer of railway ballastless track, which uses the above-mentioned wire saw cutting equipment for the filling layer of railway ballastless track and includes the following steps.

[0066] S1: Install track traveling devices 11 symmetrically on both sides of the track structure; specifically: drill holes on both sides of the track structure, install expansion bolts along the track direction, and fix the wire saw traveling track 12 to both sides of the track structure using the expansion bolts. Install the traveling bracket 13 onto the wire saw traveling track 12 via the track guide wheel 14. Install the traveling drive unit 17 onto the traveling bracket 13, and mesh the gear 171 installed on the traveling drive unit 17 with the rack 121 on the wire saw traveling track 12. Install the support wheel 16 below the traveling bracket 13 so that it contacts the wire saw traveling track 12. At this time, the traveling bracket 13 with the wire saw cutting device 21 has been installed on the wire saw traveling track 12.

[0067] S2: The diamond cable 40 is passed through a hole pre-drilled in the track structure and wound according to the configuration relationship of the active cutting unit and the driven cutting unit. Specifically, the diamond cable 40 is passed through the hole and wound sequentially around the drive wheel 24, the height-adjusting main directional wheel 261, the driven wheel 33, and the height-adjusting driven directional wheel 262 on both sides of the track structure, forming a closed loop after being connected end to end. The diamond cable 40 is tensioned to the set tension by moving the traveling bracket 13 on one side. Specifically, the wire saw cutting device 21 on one side is fixed, and the wire saw cutting device 21 on the other side is activated so that it moves appropriately on the wire saw traveling track 12 to tension the diamond cable 40.

[0068] S3: Adjust the height of the height-adjusting guide wheels 26 on the wire saw cutting devices 21 located on both sides of the track structure. Specifically, the height-adjusting guide wheels 26 achieve height adjustment by changing their installation position on the guide wheel fixing seat 25, thereby adjusting the height difference between the upper and lower cutting rope segments of the diamond rope 40 wrapped around the wheel below the track bed plate. According to the repair needs, this height difference is set to the required value: when the height difference is zero, the upper and lower cutting rope segments are parallel to each other, and the resulting block is a square block; when the height difference is non-zero, the upper and lower cutting rope segments form an incline angle in the lateral direction, and the resulting block is a wedge-shaped block. Through the above adjustments, this equipment can flexibly select to cut square blocks or wedge blocks according to the track structure damage and repair process requirements to adapt to different track replacement or filling layer repair operation needs.

[0069] S4: Under normal cutting conditions, only the main sawing power drive unit 22 on the active cutting unit is activated, which drives the diamond rope 40 to rotate. At the same time, the walking drive unit 17 is activated simultaneously, driving the walking bracket 13 to move at a constant speed along the track direction, thereby cutting the required cutting block (square block or wedge block) in one go. When the working section is a turnout area or encounters high resistance during the cutting process, the auxiliary sawing power drive unit 221 on the driven cutting unit is activated simultaneously, so that the auxiliary sawing power drive unit 221 and the main sawing power drive unit 22 operate synchronously and jointly drive the diamond rope 40 to cut, so as to ensure that the total driving torque meets the cutting requirements under high resistance conditions and maintains the stable linear speed of the diamond rope. During the entire cutting process, the output power of the main and auxiliary drive units and the traveling speed of the walking drive unit can be adjusted in real time according to the actual resistance feedback, so as to ensure a flat cutting surface, high cutting efficiency, and avoid overload of one side drive unit. During the cutting process, cooling water is sprayed onto the cutting part through cooling nozzles to reduce the cutting temperature and suppress dust.

[0070] S5: Remove the cut blocks formed by cutting, clean the cut surfaces, and temporarily support the track structure at certain intervals.

[0071] S6: Adjust the track structure after removing the cut blocks. After the track structure is adjusted, erect molds on both sides of the track structure and inject new filling material for repair.

[0072] The overall working process of the above repair method is as follows: After starting at the skylight point, first fix the wire saw travel track 12 to both sides of the track structure, and hang the travel bracket 13 equipped with the wire saw cutting device 21 on the wire saw travel track 12; then pass the diamond rope 40 through the reserved hole in the track structure, wind it up and tighten it; then use the height difference between the main directional wheel 261 and the secondary directional wheel 262 on both sides to construct a wedge-shaped cutting area with non-parallel upper and lower surfaces below the track bed slab; after starting the machine, the main sawing power drive unit 22 drives the diamond rope 40 to rotate at high speed through the drive wheel 24, and at the same time, the travel drive unit 17 pulls the entire set of equipment to move smoothly along the track direction through the gear and rack mechanism. The diamond rope 40 completes the cutting of the upper and lower surfaces in one go. In particular, the block cut by the diamond rope with the height difference is naturally wedge-shaped and has the property of self-removal from the mold. It can be taken out with a gentle pull; after taking out the block, make temporary support, adjust the track structure, erect the mold and pour in new filling material for repair. Throughout the process, the diamond rope 40 operates under the dual constraints of the drive wheel guard 51, the directional wheel guard 52, and the working grooves on both sides of the track, which controls the range of the rope breakage from the source and achieves a balance between safety and efficiency.

[0073] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A railway ballastless track filling layer wire saw cutting device, characterized in that, include: The track walking device (11) is symmetrically arranged on both sides of the ballastless track structure; The wire saw cutting device (21) is divided into an active cutting unit (210) and a driven cutting unit (220), which are respectively installed on the track walking device (11) on both sides of the track structure; The active cutting unit and the driven cutting unit respectively include a height-adjusting main directional wheel (261) and a height-adjusting driven directional wheel (262). The diamond rope (40) is wound around the height-adjusting main directional wheel (261) and the height-adjusting driven directional wheel (262) on the active cutting unit and the driven cutting unit to form two cutting rope segments below the track bed plate, which are connected end to end to form a closed loop. The track walking device (11) is used to drive the active cutting unit and the driven cutting unit to move synchronously along the track direction; The height-adjusting main guide wheel (261) and the height-adjusting secondary guide wheel (262) located on both sides of the track structure are configured to have different heights so that there is a height difference in the lateral direction between the upper and lower cutting rope segments, thereby cutting out the cutting block in one go.

2. The railway ballastless track filling layer wire saw cutting device according to claim 1, characterized in that, The track-walking device (11) includes: The wire saw travel track (12) is fixed on both sides of the ballastless track structure along the line direction, and a rack (121) is provided on the outer side of the middle part. The walking support (13) is movably mounted on the wire saw walking track (12) via the track guide wheel (14). The walking support (13) is also provided with a support wheel (16) that contacts the wire saw walking track (12). The walking drive unit (17) is fixed on the walking bracket (13), and its output end is provided with a gear (171) that meshes with the rack (121) to provide the walking bracket (13) with power to travel along the line direction.

3. The railway ballastless track filling layer wire saw cutting device according to claim 1, characterized in that, The active cutting unit, installed on one side of the track structure, includes: Main sawing power drive unit (22); drive wheel (24), driven by the main sawing power drive unit (22); The height-adjustable main directional wheel (261) is mounted on both ends of the walking bracket (13) on this side via a directional wheel fixing seat (25), and the drive wheel (24) is located between the two height-adjustable main directional wheels (261); The diamond rope (40) is wound around the height-adjusting main directional wheel (261) and the drive wheel (24).

4. The railway ballastless track filling layer wire saw cutting device according to claim 1, characterized in that, The driven cutting unit, installed on the other side of the track structure, includes: The drive wheel bracket fixing base (31) is fixed to the walking bracket (13) on this side; The drive wheel bracket (32) is mounted on the drive wheel bracket fixing base (31); From the drive wheel (33), mounted on the drive wheel bracket (32); The height adjustment is achieved by means of the directional wheel (262), which is mounted on both ends of the walking bracket (13) on this side via the directional wheel mounting base (25), and the drive wheel (33) is located between the two height adjustment directional wheels (262); The diamond rope (40) is wound around the height adjustment guide wheel (262) and the drive wheel (33).

5. The railway ballastless track filling layer wire saw cutting device according to claim 3, characterized in that, The active cutting unit also includes a direction adjustment turntable (27) for fixing the main sawing power drive unit (22). The direction adjustment turntable (27) is fixed on the walking bracket (13) and is used to adjust the installation angle of the main sawing power drive unit (22) and the drive wheel (24).

6. Railway ballastless track filling layer wire saw cutting device according to claim 3 or 4, characterized in that The height-adjusting main guide wheel (261) and the height-adjusting secondary guide wheel (262) adjust their own height by changing their installation position on the guide wheel fixing seat (25), so that the height difference between the upper and lower cutting rope segments is adjustable within the range of 0-30cm.

7. The railway ballastless track filling layer wire saw cutting device according to claim 1, characterized in that, The wire saw cutting device (21) also includes a drive wheel guard (51) and a guide wheel guard (52), which are respectively covered on the outside of the drive wheel, the height-adjusting main guide wheel (261) and the height-adjusting secondary guide wheel (262), and are used to limit the impact range of the diamond rope (40) to the working grooves on both sides of the track structure when the diamond rope (40) breaks accidentally.

8. The railway ballastless track filling layer wire saw cutting device according to claim 1, characterized in that, Both the active cutting unit and the driven cutting unit include cooling nozzles that travel together with the active cutting unit and the driven cutting unit. The cooling nozzles are connected to the coolant supply unit through pipelines.

9. The wire saw cutting equipment for the filling layer of railway ballastless track according to any one of claims 1 to 8, characterized in that, The driven cutting unit is also provided with an auxiliary sawing power drive unit (221). The auxiliary sawing power drive unit is connected to the driven wheel (33). When dual-side power drive is required, the auxiliary sawing power drive unit (221) drives the diamond rope (40) synchronously with the main sawing power drive unit (22) of the active cutting unit, so as to be suitable for turnout areas or high cutting resistance conditions.

10. A method for repairing the filling layer of railway ballastless track, characterized in that, The method of using the wire saw cutting equipment for the filling layer of railway ballastless track according to any one of claims 1 to 9 includes the following steps: S1: Install track walking devices (11) symmetrically on both sides of the track structure, fix the wire saw walking track (12) along the line direction on both sides of the track structure, and install the walking bracket (13) with the wire saw cutting device (21) on the wire saw walking track (12); S2: Pass the diamond rope (40) through the hole pre-drilled on the track structure and wind it according to the configuration relationship of the active cutting unit and the driven cutting unit. After connecting the ends, the diamond rope (40) is tensioned by moving the walking bracket (13) on one side. S3: Adjust the height of the height adjustment guide wheel (26) on the wire saw cutting device (21) located on both sides of the track structure so that the height difference between the upper and lower cutting rope segments formed by the diamond rope (40) below the track bed is the required value. The height difference can be set to zero or non-zero so as to cut out square blocks or wedge blocks respectively. S4: Start the main sawing power drive unit (22) on the active cutting unit to drive the diamond rope (40) to run, and simultaneously start the walking drive unit (17) to drive the walking bracket (13) to move along the line direction to cut into cutting blocks in one go; When the working section is a turnout area or the cutting resistance exceeds the preset threshold, the auxiliary sawing power drive unit (221) on the driven cutting unit is activated at the same time, so that the auxiliary sawing power drive unit (221) and the main sawing power drive unit (22) drive the diamond rope (40) synchronously to achieve dual-side power coordinated cutting. S5: Remove the cut blocks formed by cutting and provide temporary support for the track structure; S6: Adjust the track structure after removing the cut blocks, erect the mold, and inject new filling material for repair.

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