A method for replacing a track of a vehicle limited by a site

Abstract

This invention discloses a method for replacing overhead crane tracks under site constraints, relating to the field of industrial crane equipment technology. The method includes: determining the construction section of the overhead crane track to be replaced, and pre-arranging several replacement tracks on the track platform corresponding to the construction section; setting rail clamps at the junction of the construction section and the non-construction section; performing segmented track replacement operations, using track fixing fixtures and a lifting mechanism to lift the track to be replaced within the construction section with end constraints, moving the track to be replaced away from the track foundation, using the track fixing fixtures and the lifting mechanism to transport the replacement track to the track foundation, and aligning and installing the replacement track with the track foundation; and setting a joint connection structure at the joint of two adjacent replacement tracks to form a continuous overhead crane track. This invention divides the overhead crane track to be replaced into a first section and a second section, and constructs them sequentially according to a preset order, which helps to shorten the overall replacement cycle.

Description

Technical Field

[0001] This invention relates to the field of industrial crane equipment technology, and in particular to a method for changing crane rails in situations where space is limited. Background Technology

[0002] In industries such as steel metallurgy and heavy manufacturing, industrial plants are often long and narrow structures with overhead crane tracks running longitudinally along the plant. These tracks operate under long-term, high-load, and continuous conditions. Over time, the tracks are subjected to alternating loads, impact loads, and frictional wear, leading to cumulative damage such as rail top wear, rail head deformation, joint cracking, bolt loosening, and track deformation. Constrained by tight production schedules and limited downtime, companies often find it difficult to conduct periodic, complete replacements according to the designed lifespan. They typically resort to emergency repairs such as localized welding, clamp reinforcement, bolt tightening, and temporary welding to maintain operation. However, prolonged repairs lead to a continuous deterioration of the track condition, creating a vicious cycle of track wear, wheel damage, crane vibration, and further track wear.

[0003] Conventional overhead crane track replacement technology mainly relies on large truck cranes or mobile cranes. The work process is usually as follows: crane positions are set up along both sides of the track, the old track is removed in sections, the old track is lifted to the ground by the crane, the new track is then lifted into place by the crane, and finally, manual leveling, centering, and fixing are performed. This method can operate normally under conditions of open space, sufficient crane positions, and ample downtime. However, it has the following problems under conditions such as narrow and long workshops, limited lifting points, severely damaged tracks, and tight schedules: First, limited lifting space leads to low operational efficiency. Factory buildings are typically adjacent to production equipment, material storage areas, and safety passages, lacking suitable crane locations. Large truck cranes can only enter through limited passageways in the middle of the factory, with a single lifting point arranged longitudinally along the track. For long-distance track replacements, the crane needs to be moved repeatedly, positioned multiple times, and the lifting point adjusted, resulting in a high proportion of wasted auxiliary time.

[0004] Secondly, the removal of the old rails is difficult and poses high safety risks. The rails to be replaced have numerous fracture points and poor overall continuity, with some sections scattered in fragments. During removal, the lifting force of the cranes is difficult to distribute evenly, which can easily lead to uncontrolled breakage, sudden falls, or localized warping of the broken rails, posing a safety threat to equipment, electrical wiring, hydraulic pipelines, and personnel below the plant.

[0005] Third, the installation accuracy of the new rails is difficult to guarantee. Long-term repairs to the rails have blurred the original installation baseline, and the rail foundation has problems such as deformation and settlement. Under conventional crane lifting methods, after the new rails are in place, they need to be manually leveled and centered repeatedly. The leveling accuracy error is relatively large, which can easily lead to rail wear and severe vibration during train operation, accelerating the wear of the rails and wheels.

[0006] Fourth, there is a significant conflict with the construction schedule. Replacing long-distance railway tracks entirely using conventional techniques takes a considerable amount of time, making it difficult to meet production scheduling and order delivery requirements. Forcibly shortening the construction period, however, could easily lead to a decline in construction quality and an increase in safety risks.

[0007] Therefore, there is a need for a method for replacing railway tracks that is suitable for situations with limited space, tight schedules, and severely damaged tracks, in order to improve replacement efficiency, reduce safety risks, ensure installation accuracy, and reduce overall costs. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a method for changing train tracks that is limited by the site.

[0009] To solve the above technical problems, the technical solution of the present invention is as follows: This invention provides a method for replacing train tracks due to site constraints, the method comprising the following steps: Identify the construction section where the train track to be replaced is located, and pre-lay several replacement tracks on the track platform corresponding to the construction section; wherein, the track platform is set on the side of the train track to be replaced. Rail clamps are installed at the junction of the construction section and the non-construction section to lock the track in the non-construction section and isolate the construction section. The sectioned track replacement operation is carried out by using track fixing fixtures and lifting mechanisms to lift the track to be replaced in the construction section with constraints at both ends, and moving the track to be replaced away from the track foundation. The replacement track is then lifted to the track foundation using track fixing fixtures and lifting mechanisms, and the replacement track is aligned and installed with the track foundation. After installation, the replacement tracks are inspected for accuracy and leveled. A joint connection structure is installed at the joint of two adjacent replacement tracks to form a continuous travel track.

[0010] The beneficial effects of this invention are: (1) This invention pre-arranges several replacement rails on the track platform corresponding to the construction section, so that subsequent rail replacement work does not need to repeatedly rely on large truck cranes for lifting new rails; by symmetrically setting hand-operated hoists on both sides of the overhead crane end beam as lifting mechanisms, and using the overhead crane to transport the replacement rails to the temporary parking position above the construction section along the longitudinal movement of the overhead crane to be replaced, the overhead crane also has a longitudinal transport function, reducing the auxiliary time occupied by the repeated movement, positioning and adjustment of the lifting points of the crane. At the same time, by dividing the overhead crane to be replaced into the first section and the second section, and constructing them in sequence according to the preset order, the old rail removal, foundation cleaning, new rail installation and joint connection processes can be carried out in a segmented and streamlined manner, which is conducive to shortening the overall replacement cycle.

[0011] (2) The present invention uses a track fixing fixture to fix both ends of the track to be replaced, and sets anti-slip pads at the contact point between the track fixing fixture and the track to be replaced. Then, two hand-operated hoists are connected to both ends of the track fixing fixture and lifted synchronously, so that the track to be replaced is subjected to relatively uniform force at both ends during the lifting process, reducing uncontrollable breakage, sudden drop and local warping.

[0012] (3) After the replacement track is hoisted to the track foundation, the replacement track is aligned and installed with the track foundation, and then precision testing and leveling are performed. When the straightness, levelness, or parallelism does not meet the preset precision, the installation position of the replacement track on the track foundation is adjusted in a timely manner. By controlling the straightness, levelness, and parallelism, it is beneficial to reduce problems such as rail wear, jamming, and severe vibration during the operation of the train after replacement, reduce abnormal wear and fatigue damage of components such as wheels, reducers, and main beams of the train, and improve the smoothness of train operation and the service life of the track. Attached Figure Description

[0013] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0014] Figure 1 This is a schematic flowchart of the site-restricted vehicle track replacement method provided by the present invention. Detailed Implementation

[0015] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0016] See Figure 1 This application provides a method for replacing train tracks due to site constraints, the method comprising the following steps: Step S1: Determine the construction section of the railway track to be replaced, and pre-lay several replacement tracks on the track platform corresponding to the construction section.

[0017] Specifically, before formal construction begins, safety precautions are taken for the crane's power supply system. Procedures for shutting down the crane's overhead contact line are completed, including power outage, voltage testing, tagging, and locking. Simultaneously, a mobile crane with a rated lifting capacity meeting the requirements is selected and brought to the site.

[0018] Before construction begins at night or during off-peak production hours, a designated person directs a crane to hoist individual replacement rails to the rail platforms on both sides of the trolley. The replacement rails are spaced longitudinally along the rails to be replaced, with the spacing matching the length of each construction segment to minimize subsequent handling. After being hoisted to the rail platforms, the replacement rails are evenly distributed and securely fixed to prevent tipping or slippage.

[0019] After the replacement rail is pre-lifted and the site is confirmed to be energized, the tethering and locking of the overhead rail are released, and power is supplied to the overhead crane's rail. The crane is then moved to the area where the replacement rail is placed. Two hand-operated hoists are symmetrically attached to the anti-collision beams on both sides of the crane's end beam as lifting mechanisms. The hooks of the two hand-operated hoists are reliably connected to both ends of the replacement rail. The replacement rail is slowly lifted to a preset height. For example, the replacement rail can be lifted to a height of approximately 30cm off the ground. After lifting, the hooks, chains, and connection points are checked for security. Once confirmed to be normal, the crane is operated to travel longitudinally along the section of the overhead crane rail to be replaced, transporting the replacement rail above the section to be replaced, and then securing it at a temporary parking position.

[0020] Step S2: Install rail clamps at the junction of the construction section and the non-construction section to lock the track in the non-construction section and isolate the construction section.

[0021] Specifically, after the replacement track is delivered to its position, the trolley will be driven away from the construction area. Rail clamps will be installed at the connection point between the construction and non-construction areas. In this embodiment, high-strength rail clamps will be used. The rail clamps will be installed at the track connection point between the construction and non-construction sections, and will fix the track bidirectionally. This will lock the track within the non-construction section, preventing track displacement and isolating the construction section, thus reducing the risk of the trolley accidentally entering the construction area.

[0022] The track to be replaced is divided longitudinally into two sub-construction sections. These two sub-construction sections include a first section and a second section. In this embodiment, the approximately 450-meter-long track to be replaced is divided into a south section and a north section, with the marking machine as the boundary. The south section, designated as the first section, is approximately 220 meters long; the north section, designated as the second section, is approximately 230 meters long.

[0023] Step S3: Perform segmented rail replacement operation. Use rail fixing fixtures and lifting mechanism to lift the rail to be replaced in the construction section with constraints at both ends, and move the rail to be replaced away from the rail foundation. Use rail fixing fixtures and lifting mechanism to lift the replacement rail to the rail foundation, and align and install the replacement rail with the rail foundation.

[0024] Specifically, the first and second sections are replaced in a pre-set sequence. In this embodiment, the southern section is constructed first, completing the removal of the old rails, foundation cleaning, installation of the replacement rails, and joint welding; then the northern section is constructed, completing the removal of the old rails, foundation cleaning, installation of the replacement rails, and connection of the joint with the fish-pattern plate.

[0025] During the two construction phases, auxiliary procedures, such as spare parts transfer, tool organization, and safety monitoring, can be carried out simultaneously to improve construction efficiency.

[0026] When performing segmented rail replacement work in any section, first fix the rail fixing fixture to both ends of the rail to be replaced. Place anti-slip pads at the contact points between the rail fixing fixture and the rail to be replaced to enhance the fixing reliability and prevent slippage during lifting. Then, connect two hand-operated hoists to both ends of the rail fixing fixture. Simultaneously and slowly lift the rail to be replaced using both hand-operated hoists, ensuring relatively even force distribution at both ends of the rail. The lifting height should be controlled to not exceed 50cm. Once the rail to be replaced has been lifted to the target height, move it horizontally to the target storage point.

[0027] In this embodiment, the target storage point is the side of the track platform near the guardrail. After the track to be replaced is placed, it should be neatly arranged and securely fixed to prevent it from falling.

[0028] Subsequently, the two ends of the replacement rail are secured using a rail fixing fixture, and two hand-operated hoists are connected to the two ends of the fixture respectively. The replacement rail is lifted from its temporary parking position using the hoists and slowly moved to the base of the rail to be replaced. The surface of the rail base is cleaned to ensure the replacement rail can be smoothly lowered onto it. Simultaneously, the position of the replacement rail is manually adjusted to align the bolt holes on the replacement rail with the bolt holes on the rail base, and to ensure the centerline of the replacement rail coincides with the installation reference line. Finally, the replacement rail is slowly lowered onto the rail base for initial fixation.

[0029] Step S4: Perform precision testing and leveling on the installed replacement track, and install a joint connection structure at the joint of two adjacent replacement tracks to form a continuous travel track.

[0030] Specifically, after the replacement track is initially fixed, the accuracy of the installed replacement track is tested. A level and a theodolite are used to check the straightness, levelness, and parallelism of the replacement track. If the straightness, levelness, or parallelism does not meet the preset accuracy, the installation position of the replacement track on the track foundation is adjusted until the preset accuracy requirements are met.

[0031] In this embodiment, the preset accuracy controls are as follows: straightness less than or equal to 2mm / 10m; levelness less than or equal to 1mm / 10m; parallelism not greater than 3mm. Through accuracy testing and leveling, problems such as rail wear, jamming, and severe vibration during train operation after replacement can be reduced, thus improving the smoothness of train operation.

[0032] After precision testing and leveling meet the standards, the track clamping plates and clips are reinstalled, and the fixing bolts are tightened to ensure the replacement track is stably fixed to the track foundation. Then, a joint connection structure is installed at the joint between adjacent replacement tracks to create a reliable connection between them.

[0033] In this embodiment, for the first section, i.e., the joints of two adjacent replacement rails in the southern section, aluminothermic welding is performed. The welding temperature and time are controlled during the welding process to ensure the joint strength meets requirements. For the second section, i.e., the joints of two adjacent replacement rails in the northern section, bolt connections are performed. In this embodiment, fish-patterned bolts are used for the bolt connections to ensure a firm and smooth joint.

[0034] After the replacement rails are installed, leveled, secured, and connected within the construction section, they form a continuous crane track. The rail clamps between the construction and non-construction areas are then removed. A professional electrician removes the track tags and locks, powers the crane, and conducts a test run to check the track installation accuracy and the crane's operational status.

[0035] In addition to the above embodiments, the present invention may have other implementation methods; all technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by the present invention.

Claims

1. A method for replacing train tracks due to site constraints, characterized in that, include: The construction section of the train track to be replaced is determined, and several replacement tracks are pre-arranged on the track platform corresponding to the construction section; wherein, the track platform is set on the side of the train track to be replaced; A rail clamp is installed at the junction of the construction section and the non-construction section to lock the rail in the non-construction section and isolate the construction section. The sectioned track replacement operation is carried out by using track fixing fixtures and lifting mechanisms to lift the track to be replaced in the construction section with constraints at both ends, and moving the track to be replaced away from the track foundation. The replacement track is then lifted to the track foundation using the track fixing fixtures and lifting mechanisms, and the replacement track is aligned and installed with the track foundation. After installation, the replacement track is subjected to precision testing and leveling, and a joint connection structure is set at the joint of two adjacent replacement tracks to form a continuous travel track.

2. The method for changing train tracks under site constraints according to claim 1, characterized in that, Before using the track fixing fixture and lifting mechanism to lift the track to be replaced in the construction section with constraints at both ends, the method further includes: Two hand-operated hoists are symmetrically installed on both sides of the end beam of the crane as the lifting mechanism; Connect the hooks of the two hand chain hoists to the two ends of the new track respectively, and lift the new track to the preset height; The trolley is driven to travel longitudinally along the track to be replaced in order to transport the new track to a temporary parking position above the construction section and fix it in place.

3. The method for changing train tracks under site constraints according to claim 1, characterized in that, The process of determining the construction section in the track to be replaced includes: The track to be replaced is divided longitudinally into two sub-construction sections, which include a first section and a second section along the longitudinal direction of the track to be replaced.

4. The method for changing train tracks under site constraints according to claim 3, characterized in that, The segmented track replacement operation includes: The segmented track replacement operation is performed sequentially on at least two sub-construction sections in a preset order; The preset sequence is to first perform the segmented track replacement operation on the southern section, and then perform the segmented track replacement operation on the northern section.

5. The method for changing train tracks under site constraints according to claim 1, characterized in that, The method of setting a joint connection structure at the joint of two adjacent new tracks includes: Aluminum thermofusion welding is performed at the joint of two adjacent replacement rails in the first section, and bolt connection is performed at the joint of two adjacent replacement rails in the second section.

6. The method for changing train tracks under site constraints according to claim 2, characterized in that, The method of using track fixing fixtures and a lifting mechanism to lift the track to be replaced within the construction section by restraining both ends includes: Remove the track pressure plates, fixing bolts, and spring washers on both sides of the track to be replaced; The track fixing fixture is fixed to both ends of the track to be replaced, and anti-slip pads are provided at the contact points between the track fixing fixture and the track to be replaced. Connect the two hand chain hoists to the two ends of the track fixing fixture respectively, and simultaneously lift the track to be replaced; When the track to be replaced is lifted to a height of no more than 50cm, the old track is moved to the target storage point for fixed storage.

7. The method for changing train tracks under site constraints according to claim 1, characterized in that, The process of precision testing and leveling the newly installed track includes: The straightness, levelness, and parallelism of the replacement track were checked using a level and a theodolite. When the straightness, levelness, or parallelism does not meet the preset accuracy, the installation position of the replacement track on the track base is adjusted.

8. The method for changing train tracks under site constraints according to claim 7, characterized in that, The preset accuracy includes: straightness less than or equal to 2mm / 10m, horizontality less than or equal to 1mm / 10m, and parallelism not less than or equal to 3mm.

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