A gantry rail unloading and replacement system

Abstract

The application discloses a gantry type rail unloading and replacing operation system, which comprises a rail car for providing traction power, new rails to be replaced, a rail loading and unloading device for hoisting and transporting the new rails, a plurality of general flat cars for loading the new rails and the rail loading and unloading device, and the rail loading and unloading device is installed on the general flat car. The rail loading and unloading device comprises a group hoisting system composed of multiple gantry hoisting devices, the gantry hoisting devices are loaded on multiple general flat cars in a distributed manner, are synchronously combined and transported with the new rails to be replaced, and the two ends of the general flat car are connected with the rail car to realize walking traction. The rail loading and unloading device further comprises a folding and unfolding mechanism, the multiple gantry hoisting devices are synchronously placed on a line through the folding and unfolding mechanism and are synchronously recovered to the general flat car. The application can solve the technical problems that the existing rail transport car has single construction organization, limited functions, high operation difficulty and long sky window time occupation.

Description

Technical Field

[0001] This application relates to the field of track engineering machinery technology, and is applied to large-scale railway maintenance machinery, and in particular to a rail unloading and replacement operation system using gantry crane for railway track maintenance and construction. Background Technology

[0002] High-speed rail tracks, after a long period of service, have suffered damage and wear in some areas due to varying geological conditions, climate, and operating conditions. Replacing high-speed rail tracks has become a routine part of track maintenance. While railway engineering departments have begun small-scale replacement and repair work on high-speed rail tracks, this is still insufficient to meet the ever-increasing demand for track replacement.

[0003] The ultimate repair method for damaged rails is rail replacement. Currently, this is often done by inserting a 25m rail and connecting it using aluminothermic welding or mobile flash welding. When the replacement length exceeds 25 meters, multiple standard 25m rails need to be unloaded and moved to the side of the track beforehand. These rails are then welded into long rails on-site and replaced manually, resulting in low construction efficiency and high labor intensity. Furthermore, inserting short rails for track repair increases the number of welds and damages existing 100m or other length rails. When using a railcar with a crane for rail replacement, the limited vehicle formation only provides two lifting points, making it difficult to lift rails longer than 25 meters, and it also requires the use of adjacent track resources.

[0004] To address the aforementioned technical challenges, some lines employ a method where short rails are welded into long rails at the factory, which are then transported directly to the site by long rail transport vehicles for installation. This saves significant construction time, and the welding quality is better when done at the factory. There is an urgent need for 100-meter or other length rails in on-site rail replacement operations, but loading, unloading, and transportation present difficulties, and existing equipment is insufficient to meet on-site construction needs. Currently, mechanized operations with large rail replacement vehicles are mainly for major rail overhauls involving continuous replacement of 1km or more. Small-scale rail replacement operations still rely primarily on manual labor with simple tools, resulting in high labor intensity and potential damage to the rail base during the replacement process.

[0005] Existing long rail transport trainsets can be broadly categorized as follows: One type uses longitudinal rail loading and unloading, with a mobile rail loading and unloading device equipped with a robotic arm mounted on the train. This type of train can transport and unload long rails on small-radius curves, is less affected by construction and track conditions, and can perform unidirectional, off-site rail loading and unloading. However, due to its structure, the construction organization for this type of train is relatively simple. Furthermore, the movement of the rail loading and unloading device within the train poses safety hazards. Another type uses lateral rail loading and unloading on the same side. This type of train is formed by connecting multiple flatbed trucks equipped with rail lifting and rail-bearing devices. These trainsets can be coupled together using lifting devices, allowing for simultaneous lifting and lateral movement of rails from both sides of the train for loading and unloading. However, this type of train can only perform loading and unloading on the same side and cannot perform off-site rail loading and unloading. The third type uses a centralized gantry crane system for transporting long rails. The gantry cranes are placed on top of a set of flatcars, and multiple gantry cranes are used to unload and retrieve the long rails. During construction, this type of long rail transport requires moving railcars sequentially for placement, which takes a considerable amount of time. Furthermore, retrieving the gantry cranes also requires moving the railcars multiple times for alignment, making the operation more difficult and requiring a longer deployment window. Summary of the Invention

[0006] In view of this, the purpose of this application is to provide a gantry-type rail unloading and replacement operation system to solve the technical problems of existing rail transport vehicles having simple construction organization, limited functions, high operational difficulty, and long maintenance window time.

[0007] To achieve the aforementioned objectives, this application specifically provides a technical solution for a gantry-type rail unloading and replacement system, including: Railcars used to provide traction power; New rails to be replaced; Rail loading and unloading equipment used for hoisting and transporting new rails; Several general-purpose flatbed cars for loading new rails and rail loading and unloading equipment are attached to the rail car, and the rail loading and unloading equipment is installed on the general-purpose flatbed cars.

[0008] The rail loading and unloading device includes a group lifting system composed of multiple gantry cranes, the number of which is adapted to the lifting of new rails of different lengths. The gantry cranes are loaded in a distributed manner on multiple general-purpose flatbed cars and transported synchronously with the new rails to be replaced. Railcars are attached to both ends of the general-purpose flatbed cars for traction.

[0009] The rail loading and unloading device also includes a take-up and release mechanism, which enables multiple gantry crane devices to be placed on the track simultaneously and retrieved to a general-purpose flatbed truck simultaneously.

[0010] Furthermore, the group crane system includes multiple sets of gantry crane devices with identical structures, which are fixedly installed in the middle of a general-purpose flatbed truck. During transport, the length direction of each gantry crane device aligns with the direction of the route.

[0011] Furthermore, the gantry crane device includes outriggers, a main lifting cylinder, a crossbeam, a lifting mechanism, an auxiliary lifting cylinder, and a load-bearing beam. The outriggers are located on both sides of the crossbeam along its length, the load-bearing beam is located at the bottom of the outriggers, and the auxiliary lifting cylinders are located on both sides of the load-bearing beam along its length. The outriggers employ a two-stage guide column nested telescopic structure, and the main lifting cylinder is located between the two stages of guide columns. The lifting mechanism is mounted on the crossbeam and has its own propulsion, enabling horizontal movement along the crossbeam. Driven by the main and auxiliary lifting cylinders, the height travel of the outriggers can be adjusted within a set range.

[0012] Furthermore, the retraction mechanism includes a connecting beam, a base, a traveling trolley, a power system, a lifting column, a rotating device, a leveling mechanism, and a lifting drive mechanism. The base is located at both ends of the connecting beam along its length and is fixedly connected to a general-purpose flatbed cart. The traveling trolley is mounted on the connecting beam. The power system is mounted on the traveling trolley, the lifting column is mounted on the traveling trolley, and the rotating device is located at the top of the lifting column. The leveling mechanism is mounted on the rotating device. The lifting column adopts a two-stage guide column nested telescopic structure, and the lifting drive mechanism is located between the two stages of guide columns. The lifting operation of the lifting column is achieved through the telescopic movement of the lifting drive mechanism.

[0013] Furthermore, the base is also equipped with fixing slots for securing the outriggers of the gantry crane device during transport. During the placement of the gantry crane device, the lifting column pushes the device out of the fixing slots to avoid obstacles below and prevent interference or collisions during rotation. The rotating device is driven by a hydraulic motor to rotate the slewing bearing. After the gantry crane device is lifted to a set height by the lifting column, the rotating device rotates the device 90°, switching it from transport to operating posture.

[0014] Furthermore, the leveling mechanism also includes a gantry crane take-up and drop slot, a mounting base, and a leveling drive mechanism. The gantry crane take-up and drop slot is used to place the crossbeam of the gantry crane device. The mounting base is located on the top of the lifting column, and the top of the mounting base is hinged to the bottom of the gantry crane take-up and drop slot. The leveling drive mechanism is hinged to the ends of the gantry crane take-up and drop slot and the mounting base on the same side along the length direction. The leveling mechanism, through the leveling drive mechanism, realizes the tilt angle adjustment of the left and right sides within a set range, compensating for the inconsistent left and right heights of the general flatbed truck frame plane.

[0015] Furthermore, the traveling trolley includes a chain, a drive motor, a grooved guide rail, traveling wheels, and a sprocket. The grooved guide rail is mounted on the connecting beam. The traveling trolley engages with the grooved guide rail via the traveling wheels, and the drive motor drives the sprocket to mesh with the chain, enabling the traveling trolley to move longitudinally along the grooved guide rail. The traveling trolley, via the drive motor, allows for position adjustment of the gantry crane during placement or for compensating for parking errors in the alignment of the railcar during the gantry crane's retrieval.

[0016] Furthermore, the general-purpose flatbed vehicle is equipped with several rail locking devices along the track direction, which are used for placing, locking, and transporting new rails.

[0017] Furthermore, during the new rail replacement operation, the rail locking device is first unlocked, and then the gantry crane is lifted to a set height using the lifting mechanism. It is then rotated 90° to align the gantry crane's beam with the sleeper. Once sufficient space is available on both sides of the track, the gantry crane's outriggers are lowered to contact the ground, ensuring a stable placement on the track. The lifting mechanism is then lowered back to its initial position, completing the placement of the gantry crane.

[0018] Furthermore, each set of rail loading and unloading devices' gantry crane and its take-up and drop-off mechanisms are individually controlled to ensure that multiple sets of rail loading and unloading devices can be simultaneously operated by multiple people during construction. The lifting mechanism of the gantry crane can be switched between local operation and centralized control, allowing for selection of individual or centralized control modes based on site conditions.

[0019] By implementing the technical solution of the gantry rail unloading and replacement system provided in this application, the following beneficial effects are achieved: (1) The gantry rail unloading and replacement operation system of this application adopts a group lifting system composed of multiple mobile gantry cranes. The gantry cranes are distributed and installed on the transport flatcar. During the rail loading and unloading operation, the 100-meter-long rail can be smoothly and quickly loaded and unloaded from the flatcar, meeting the on-site construction needs. Through the synchronous operation of multiple gantry cranes, the deployment can be quickly realized to form a group lifting system, which can realize the smooth lifting of rail components, reduce rail component deformation, and reduce the safety risks of lifting. (2) In the gantry rail unloading and replacement system of this application, after the rail unloading is completed, the rail transport vehicle is assembled and withdrawn from the operation area. The group lifting system composed of multiple gantry cranes can easily lift the old long rails off the line and replace them with new long rails, which greatly reduces the number of operators and labor intensity. The special lifting tools can effectively protect the rails from damage; effectively improve the efficiency of long rail replacement, reduce the labor intensity of rail replacement operation, and protect the rails from damage by operating equipment. (3) The gantry rail unloading and replacement operation system of this application does not require the setting of a special transport flatcar, which reduces the length of the vehicle group; the group lifting scheme composed of multiple gantry cranes can flexibly realize the setting of multiple lifting points on the line without intruding on the adjacent line, and the group lifting system can freely increase or decrease the number of lifting points according to the length of the long rail to complete the rail unloading, replacement and collection operation. It can be flexibly laid out and freely combined to realize the unloading, replacement and collection operation of long rail on the line. (4) The gantry rail unloading and replacement system of this application arranges the gantry crane evenly on the long rail transport vehicle in a distributed manner to realize the combined transportation of the device and the material; in order to realize the parallel and synchronous operation of multiple gantry cranes during the loading and unloading operation, only one alignment of the rail vehicle is required to complete the simultaneous placement or recovery operation of multiple cantilever cranes, which greatly reduces the preparation time and improves the construction efficiency. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of a specific embodiment of the rail unloading and replacement vehicle used in the gantry rail unloading and replacement operation system of this application; Figure 2 This is a schematic diagram of the structure of a rail loading and unloading device according to a specific embodiment of the gantry-type rail unloading and replacement system of this application; Figure 3 This is a schematic diagram of the working principle of a specific embodiment of the gantry-type rail unloading and replacement system of this application. Figure 1 ; Figure 4 This is a schematic diagram of the working principle of a specific embodiment of the gantry-type rail unloading and replacement system of this application. Figure 2 ; Figure 5 This is a structural schematic diagram of a gantry crane device, representing a specific embodiment of the gantry rail unloading and replacement system of this application. Figure 6 This is a schematic diagram of the take-up and take-down mechanism of a specific embodiment of the gantry rail unloading and replacement system of this application; Figure 7 This is a schematic diagram of the leveling mechanism of a specific embodiment of the gantry rail unloading and replacement system of this application; Figure 8 This is a schematic diagram of the traveling trolley of a specific embodiment of the gantry rail unloading and replacement system of this application; Figure 9This is a structural schematic diagram of a specific embodiment of the gantry rail unloading and replacement operation method based on the system of this application, under the vehicle marshalling and disassembly state. Figure 10 This is a structural schematic diagram of the gantry crane device in its placement state, based on a specific embodiment of the gantry rail unloading and replacement operation method of the system in this application. Figure 11 This application Figure 10 A partially enlarged structural diagram; Figure 12 This is a structural schematic diagram of a gantry crane device in the hoisting state, based on a specific embodiment of the gantry rail unloading and replacement operation method of the system in this application. Figure 13 This is a schematic diagram of the gantry crane device in the recovery state, based on a specific embodiment of the gantry rail unloading and replacement operation method of the system in this application. In the diagram: 1-railcar, 2-general-purpose flatbed car, 3-rail loading and unloading device, 31-gantry crane device, 311-outrigger, 312-main lifting cylinder, 313-crossbeam, 314-lifting mechanism, 315-auxiliary lifting cylinder, 316-bearing beam, 32-retrieval mechanism, 320-connecting beam, 321-base, 322-traveling trolley, 323-power system, 324-lifting column, 325-rotating device, 326-leveling mechanism, 327-fixed slot, 328-gantry crane retrieval slot, 329-mounting base, 330-leveling drive mechanism, 331-chain, 332-drive motor, 333-slotted guide rail, 334-traveling wheel, 335-sprocket, 336-lifting drive mechanism, 4-new rail, 5-rail locking device, 6-track, 7-sleeper, 8-old rail. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0023] As attached Figure 1 To be continued Figure 13 As shown, a specific embodiment of the gantry rail unloading and replacement operation system of this application is given. The application will be further described below with reference to the accompanying drawings and specific embodiments.

[0024] Example 1 As attached Figure 1 To be continued Figure 9As shown, an embodiment of the gantry-type rail unloading and replacement system of this application specifically includes: Railcar 1 used to provide traction power; 4 new steel rails to be replaced; Rail loading and unloading device 3 for hoisting and transporting new rails 4; Several general-purpose flatbed cars 2 are attached to railcar 1 for loading new rails 4 and rail loading and unloading devices 3. The rail loading and unloading devices 3 are installed on the general-purpose flatbed cars 2.

[0025] The rail loading and unloading device 3 further includes a group lifting system composed of multiple sets of gantry crane devices 31 with the same structure. The number of gantry crane devices 31 is adapted to the lifting of new rails 4 of different lengths. The gantry crane devices 31 are loaded in a distributed manner on multiple general-purpose flatbed cars 2 and transported synchronously with the new rails 4 to be replaced. Rail cars 1 are attached to both ends of the general-purpose flatbed cars 2 for traction.

[0026] As attached Figure 2 To be continued Figure 4 As shown, the group crane system includes multiple sets of gantry crane devices 31 with identical structures, which are fixedly installed in the middle of the general-purpose flatbed car 2. In transport mode, the length direction of the gantry crane devices 31 is aligned with the direction of the track 6. The rail loading and unloading device 3 also includes a take-up and drop mechanism 32, which enables the simultaneous placement of multiple sets of gantry crane devices 31 on the track 6 and their simultaneous return to the general-purpose flatbed car 2.

[0027] As attached Figure 5 As shown, the gantry crane device 31 further includes outriggers 311, a main lifting cylinder 312, a crossbeam 313, a lifting mechanism 314, an auxiliary lifting cylinder 315, and a load-bearing beam 316. The outriggers 311 are located on both sides of the crossbeam 313 along its length, the load-bearing beam 316 is located at the bottom of the outriggers 311, and the auxiliary lifting cylinders 315 are located on both sides of the load-bearing beam 316 along its length. The outriggers 311 adopt a two-stage guide column nested telescopic structure, with the main lifting cylinder 312 located between the two stages of guide columns. The lifting mechanism 314 is mounted on the crossbeam 313 and can further employ a self-propelled electric hoist, enabling horizontal movement along the crossbeam 313. Driven by the main lifting cylinder 312 and the auxiliary lifting cylinder 315, the height travel of the outriggers 311 can be adjusted within a set range.

[0028] As attached Figure 6As shown, the retraction mechanism 32 further includes a connecting beam 320, a base 321, a traveling trolley 322, a power system 323, a lifting column 324, a rotating device 325, a leveling mechanism 326, and a lifting drive mechanism 336. The base 321 is a rigid structural component, located at both ends of the connecting beam 320 along its length and fixedly connected to the general-purpose flatbed trolley 2. The traveling trolley 322 is mounted on the connecting beam 320. The power system 323 is mounted on the traveling trolley 322, the lifting column 324 is mounted on the traveling trolley 322, and the rotating device 325 is located on the top of the lifting column 324. The leveling mechanism 326 is mounted on the rotating device 325. The lifting column 324 adopts a two-stage guide column nested telescopic structure, and the lifting drive mechanism 336 is located between the two stages of guide columns. The lifting operation of the lifting column 324 is achieved through the telescopic movement of the lifting drive mechanism 336.

[0029] The base 321 is also provided with fixing slots 327 for securing the outriggers 311 of the gantry crane device 31 in the transport state. During the placement of the gantry crane device 31, the lifting column 324 pushes the gantry crane device 31 out of the fixing slots 327 to avoid obstacles below and prevent interference and collisions during rotation. The rotating device 325 is driven by a hydraulic motor to rotate the slewing bearing. After the gantry crane device 31 is lifted to the set height by the lifting column 324, the rotating device 325 rotates the gantry crane device 31 90° to switch the transport posture to the working posture.

[0030] As attached Figure 7 As shown, the leveling mechanism 326 further includes a gantry crane deployment / retraction slot 328, a mounting base 329, and a leveling drive mechanism 330. The gantry crane deployment / retraction slot 328 is used to place the crossbeam 313 of the gantry crane device 31. The mounting base 329 is located on the top of the lifting column 324, and the top of the mounting base 329 is hinged to the bottom of the gantry crane deployment / retraction slot 328. The leveling drive mechanism 330 is hinged to the ends of the gantry crane deployment / retraction slot 328 and the mounting base 329 on the same side along the length direction. The leveling mechanism 326 achieves tilt angle adjustment on both sides within a set range through the leveling drive mechanism 330, so as to solve the problem of inconsistent left and right heights of the two planes of the general-purpose flatbed truck when operating under ultra-high conditions on the line, and realize that the gantry crane device 31 can be vertically deployed and retrieved under all working conditions.

[0031] As attached Figure 8As shown, the traveling trolley 32 further includes a chain 331, a drive motor 332, a grooved guide rail 333, traveling wheels 334, and a sprocket 335. The grooved guide rail 333 is mounted on the connecting beam 320. The traveling trolley 32 engages with the grooved guide rail 333 via the traveling wheels 334. The drive motor 332 drives the sprocket 335 to mesh with the chain 331, enabling the traveling trolley 32 to move longitudinally along the grooved guide rail 333. The traveling trolley 32, via the drive motor 332, allows for small-range adjustments to the position of the gantry crane device 31 during placement, or compensation for parking errors in the alignment of the railcar 1 during the gantry crane device 31's retrieval. Precise positioning can be achieved by controlling the movement of the traveling trolley 32.

[0032] The general-purpose flatbed 2 is equipped with several rail locking devices 5 along the track direction. The rail locking devices 5 are used for placing, locking and transporting new rails 4.

[0033] During the replacement of the new rail 4, the rail locking device 5 is first unlocked. Then, the gantry crane device 31 is lifted to the set height by the lifting mechanism 32. It is then rotated 90° to align the crossbeam 313 of the gantry crane device 31 with the sleeper 7. Once it is confirmed that there is sufficient space on both sides of the track 6 for lowering, the outriggers 311 of the gantry crane device 31 are lowered to contact the ground, ensuring a stable placement on the track 6. The lifting mechanism 32 is then lowered to its initial position, completing the placement of the gantry crane device 31. For retrieval, the horizontal and vertical adjustments of the lifting mechanism 32 are used to align the position of the gantry crane device 31, and the placement operation is then reversed to complete the retrieval of the gantry crane device 31.

[0034] Each set of rail loading and unloading devices 3, including the gantry crane 31 and the take-up and drop mechanism 32, is individually controlled to ensure that multiple sets of rail loading and unloading devices 3 can be simultaneously operated by multiple people during construction. The lifting mechanism 314 of the gantry crane 31 can be switched between local operation and centralized control, allowing for individual or centralized control depending on the site conditions, thereby maximizing operational efficiency.

[0035] It should be noted that the main lifting electric cylinder 312 and the auxiliary lifting electric cylinder 315 can also be hydraulic cylinders, pneumatic cylinders, etc., and the leveling drive mechanism 330 and the lifting drive mechanism 336 can also be hydraulic cylinders, pneumatic cylinders, electric cylinders, etc. The number of general-purpose flatbed cars 2 is determined according to the length of the rail components to be replaced, and the number of rail loading and unloading devices 3 can also be configured accordingly. Any combination of different numbers of flatbed cars is within the scope of protection claimed in this application. The lifting, rotation, and longitudinal movement of the retraction mechanism 32 can all be driven by hydraulic cylinders. Any mechanism that can achieve this function under the same conditions, such as using electric or pneumatic actuators, is within the scope of protection claimed in this application. The outrigger extension function in the gantry crane device 31 uses one main extension section and two auxiliary extension sections to achieve the lifting stroke, which only represents one type of outrigger structure. Any motion mechanism that can meet the retraction stroke, such as using single-stage extension or folding retraction, is within the scope of protection claimed in this application. The gantry crane device 31’s retraction and extension functions and outrigger lifting functions are controlled by local independent operation, while the lateral movement and lifting of the hoisting mechanism 314 are controlled by local / centralized control. This is the optimal method to maximize construction efficiency. Any other implementation scheme that can meet the construction operation requirements is within the scope of protection claimed in this application.

[0036] The gantry-type rail unloading and replacement system described in this embodiment is suitable for loading, unloading, and transporting long rails (such as 100-meter rails). The system consists of multiple sets of mobile gantry cranes 31 forming a group lifting system. These systems are distributed and loaded onto multiple general-purpose flatbed cars 2, and are transported synchronously with the new rails 4 to be replaced. Railcars 1 are attached to both ends of the general-purpose flatbed cars 2 for traction. The entire vehicle formation includes railcars 1 (providing traction power), general-purpose flatbed cars 2 (for loading long rails and rail loading / unloading devices 3), rail loading / unloading devices 3 (installed on the general-purpose flatbed cars 2 for lifting and transporting long rails), and the new rails 4 to be replaced (i.e., the work object). The number of gantry cranes 31 in different formations accommodates the lifting of rails of varying lengths.

[0037] The gantry-type rail replacement system described in this embodiment employs a synchronous hoisting scheme using multiple gantry crane units 31. The required number of gantry crane units 31 can be freely selected based on the length of the rail to be replaced, enabling multiple units to be connected. It features unloading new rails from both sides of long rails and recovering old rails, overcoming the shortcomings of existing rail unloading devices, such as limited functionality and inability to unload rails from opposite sides. This provides a completely new technical solution for rail replacement on high-speed railway lines. Furthermore, by configuring different numbers of gantry crane units 31 according to on-site rail requirements, different lengths of rails can be replaced, replacing the existing 25m rail replacement method. This significantly reduces the number of welds on the track, effectively ensuring the safety of track operation.

[0038] Example 2 As attached Figure 9 and appendix Figure 13 As shown, an embodiment of a gantry rail unloading and replacement operation method based on the operating system described in Embodiment 1 specifically includes the following steps: S1) The railcar 1 pulls the entire train of vehicles from the station to the construction point. After the new rail 4 on the general flatbed car 2 is aligned with the old rail 8 on the ground to be replaced, the railcar 1 and the general flatbed car 2 are separated. S2) After the gantry crane device 31 is locked and released, each of the raising and lowering mechanisms 32 lifts and rotates the gantry crane device 31 and places it on the line 6. S3) After confirming that the gantry crane device 31 is placed stably, the new steel rail 4 is lifted by the lifting mechanism 314 of multiple gantry crane devices 31 and placed next to the track 6. Then, another railcar 1 pulls the general flatbed car 2 out of the work area. S4) After manually removing the fasteners of the old rail 8 on line 6, use multiple sets of gantry cranes 31 to lift the old rail 8 out of the rail bearing groove, and then lift the new rail 4 from the side of line 6 into the rail bearing groove to complete the rail replacement. S5) After the rail replacement and track restoration are completed, the railcar 1 pulls the general flatbed 2 into the construction area. After the second alignment is completed, the gantry crane 31 lifts the old rail 8 that has been replaced onto the general flatbed 2. Then, the gantry crane 31 is retrieved onto the general flatbed 2 by the take-up and put-down mechanism 32 and locked into the transport state. S6) The railcar 1 and the general flatbed car 2 are coupled together, and after the train is reassembled, the entire train is pulled back to the station.

[0039] The gantry crane device 31 is fixedly installed in the middle of the general-purpose flatbed truck 2. In the transportation state, the length direction of the gantry crane device 31 is consistent with the direction of the line 6.

[0040] Several rail locking devices 5 are installed along the track direction on the general flatbed 2. The rail locking devices 5 are used for placing, locking and transporting new rails 4.

[0041] The gantry crane device 31 further includes outriggers 311, a main lifting cylinder 312, a crossbeam 313, a lifting mechanism 314, an auxiliary lifting cylinder 315, and a load-bearing beam 316. Outriggers 311 are installed on both sides of the crossbeam 313 along its length. The load-bearing beam 316 is installed at the bottom of the outriggers 311, and auxiliary lifting cylinders 315 are installed on both sides of the load-bearing beam 316 along its length. The outriggers 311 adopt a two-stage guide column nested telescopic structure, with the main lifting cylinder 312 installed between the two stages of guide columns. The lifting mechanism 314 is installed on the crossbeam 313, and the lifting mechanism 314 has its own propulsion, enabling horizontal movement along the crossbeam 313. Driven by the main lifting cylinder 312 and the auxiliary lifting cylinder 315, the height travel of the outriggers 311 can be adjusted within a set range.

[0042] The retraction mechanism 32 further includes a connecting beam 320, a base 321, a traveling trolley 322, a power system 323, a lifting column 324, a rotating device 325, a leveling mechanism 326, and a lifting drive mechanism 336. Bases 321 are provided at both ends of the connecting beam 320 along its length, and the bases 321 are fixedly connected to the general-purpose flatbed trolley 2. The traveling trolley 322 is mounted on the connecting beam 320. The power system 323 is mounted on the traveling trolley 322, and the lifting column 324 is mounted on the traveling trolley 322. A rotating device 325 is mounted on the top of the lifting column 324. The leveling mechanism 326 is mounted on the rotating device 325. The lifting column 324 adopts a two-stage guide column nested telescopic structure, and the lifting drive mechanism 336 is located between the two stages of guide columns. The lifting operation of the lifting column 324 is achieved through the telescopic movement of the lifting drive mechanism 336.

[0043] A fixing slot 327 is provided on the base 321 for securing the outriggers 311 of the gantry crane device 31 in the transport state. During the placement of the gantry crane device 31, the lifting column 324 pushes the gantry crane device 31 out of the fixing slot 327 to avoid obstacles below and prevent interference and collisions during rotation. The rotating device 325 is driven by a hydraulic motor to rotate the slewing bearing. After the gantry crane device 31 is lifted to the set height by the lifting column 324, the rotating device 325 rotates the gantry crane device 31 by 90° to switch the transport posture to the working posture.

[0044] The leveling mechanism 326 further includes a gantry crane take-up and drop trough 328, a mounting base 329, and a leveling drive mechanism 330. The gantry crane take-up and drop trough 328 is used to place the crossbeam 313 of the gantry crane device 31. The mounting base 329 is provided on the top of the lifting column 324, and the top of the mounting base 329 is hinged to the bottom of the gantry crane take-up and drop trough 328. The leveling drive mechanism 330 is hinged to the ends of the gantry crane take-up and drop trough 328 and the mounting base 329 on the same side along the length direction. The leveling mechanism 326 realizes the tilt angle adjustment of the left and right sides within a set range through the leveling drive mechanism 330 to compensate for the inconsistency in the left and right height of the general flatbed truck 2 frame plane.

[0045] The traveling trolley 32 further includes a chain 331, a drive motor 332, a grooved guide rail 333, traveling wheels 334, and a sprocket 335. The grooved guide rail 333 is provided on the connecting beam 320. The traveling trolley 32 engages with the grooved guide rail 333 via the traveling wheels 334. The drive motor 332 drives the sprocket 335 to mesh with the chain 331, enabling the traveling trolley 32 to move longitudinally along the grooved guide rail 333. The traveling trolley 32, via the drive motor 332, allows for position adjustment of the gantry crane device 31 during placement or to compensate for parking errors in the alignment of the railcar 1 during the gantry crane device 31's retrieval.

[0046] During the unloading and replacement of long rail 4, the rail locking device 5 is first unlocked, and then the gantry crane device 31 is lifted to the set height by the lifting mechanism 32. After that, it is rotated 90° so that the crossbeam 313 of the gantry crane device 31 is aligned with the direction of the sleeper 7. After confirming that there is space on both sides of the track 6 for lowering, the outriggers 311 of the gantry crane device 31 are lowered to contact the ground to ensure that it is placed stably on the track 6. Then, the lifting mechanism 32 is lowered to the initial position to complete the placement of the gantry crane device 31.

[0047] Each set of rail loading and unloading devices 3 has its gantry crane 31 and its take-up and drop mechanism 32 controlled by individual operation to ensure that multiple sets of rail loading and unloading devices 3 can be carried out simultaneously by multiple people during construction operations. The lifting mechanism 314 of the gantry crane 31 can be switched between local operation and centralized control, and the individual control or centralized control mode can be selected according to the site conditions.

[0048] In the description of this specification, the references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0049] In the description of this application, it should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly set on the other element or indirectly set on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element.

[0050] It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0051] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" or "several" means two or more, unless otherwise explicitly specified.

[0052] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only used to complement the content disclosed in the specification for those skilled in the art to understand and read, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this application can produce, should still fall within the scope of the technical content disclosed in this application.

[0053] By implementing the technical solution of the gantry rail unloading and replacement system described in the specific embodiments of this application, the following technical effects can be achieved: (1) The gantry rail unloading and replacement operation system described in the specific embodiments of this application adopts a group lifting system composed of multiple mobile gantry cranes. The gantry cranes are distributed and installed on the transport flatcar. During the rail loading and unloading operation, the 100-meter-long rail can be smoothly and quickly loaded and unloaded from the flatcar, meeting the on-site construction needs. Through the synchronous operation of multiple gantry cranes, the deployment can be quickly realized to form a group lifting system, which can realize the smooth lifting of rail components, reduce rail component deformation, and reduce the safety risks of lifting. (2) The gantry rail unloading and replacement system described in the specific embodiments of this application, after the rail unloading is completed, the rail transport vehicle group withdraws from the operation area. The group lifting system composed of multiple gantry cranes can easily lift the old long rails off the line and replace them with new long rails, greatly reducing the number of operators and labor intensity. The special lifting tools can effectively protect the rails from damage; effectively improve the efficiency of long rail replacement, reduce the labor intensity of rail replacement operations, and protect the rails from damage by operating equipment. (3) The gantry rail unloading and replacement operation system described in the specific embodiments of this application does not require the setting of a special transport flatcar, which reduces the length of the vehicle group; the group lifting scheme composed of multiple gantry cranes can flexibly realize the setting of multiple lifting points on the line without intruding on the adjacent line, and the group lifting system can freely increase or decrease the number of lifting points according to the length of the long rail to complete the rail unloading, replacement and collection operations. It can be flexibly laid out and freely combined to realize the unloading, replacement and collection operations of long rails on the line. (4) The gantry rail unloading and replacement system described in the specific embodiments of this application arranges the gantry cranes evenly on the long rail transport vehicle in a distributed manner to realize the combined transportation of the device and the material. In the process of loading and unloading, in order to realize the parallel and synchronous operation of multiple gantry cranes, only one alignment of the rail vehicle is required to complete the synchronous placement or recovery operation of multiple cantilever cranes, which greatly reduces the preparation time and improves the construction efficiency.

[0054] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0055] The above description is merely a preferred embodiment of this application and is not intended to limit this application in any way. Although this application has been disclosed above with reference to preferred embodiments, it is not intended to limit this application. Any person skilled in the art can make many possible variations and modifications to the technical solutions of this application using the methods and techniques disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the spirit and technical essence of this application. Therefore, any simple modifications, equivalent substitutions, equivalent changes, and modifications made to the above embodiments based on the technical essence of this application without departing from the content of the technical solutions of this application shall still fall within the protection scope of the technical solutions of this application.

Claims

1. A gantry-type rail unloading and replacement system, characterized in that, include: Railcar used to provide traction power (1); New steel rails to be replaced (4); Rail loading and unloading device (3) for hoisting and transporting new rails (4); A number of general-purpose flatbed cars (2) are attached to the railcar (1) for loading new rails (4) and rail loading and unloading devices (3), and the rail loading and unloading devices (3) are installed on the general-purpose flatbed cars (2); The rail loading and unloading device (3) includes a group lifting system composed of multiple sets of gantry crane devices (31). The number of gantry crane devices (31) is adapted to the lifting of new rails (4) of different lengths. The gantry crane devices (31) are loaded on multiple general-purpose flatbed cars (2) in a distributed manner and transported synchronously with the new rails (4) to be replaced. The two ends of the general-purpose flatbed cars (2) are connected to railcars (1) for traction. The rail loading and unloading device (3) also includes a take-up and release mechanism (32), through which multiple sets of gantry crane devices (31) are simultaneously placed on the track (6) and simultaneously retrieved to a general flatbed car (2).

2. The gantry-type rail unloading and replacement system according to claim 1, characterized in that: The group crane system includes multiple sets of gantry crane devices (31) with the same structure. The gantry crane devices (31) are fixedly installed in the middle of the general flatbed truck (2). In the transportation state, the length direction of the gantry crane device (31) is consistent with the direction of the line (6).

3. The gantry-type rail unloading and replacement system according to claim 1 or 2, characterized in that: The gantry crane device (31) includes outriggers (311), main lifting cylinders (312), crossbeams (313), lifting mechanisms (314), auxiliary lifting cylinders (315), and load-bearing beams (316). The outriggers (311) are located on both sides of the crossbeams (313) along their length. The load-bearing beams (316) are located at the bottom of the outriggers (311). The auxiliary lifting cylinders (315) are located on both sides of the load-bearing beams (316) along their length. The outriggers (311) adopt a two-stage guide column nested telescopic structure. The main lifting cylinders (312) are located between the two stages of guide columns. The lifting mechanism (314) is located on the crossbeams (313). The lifting mechanism (314) has its own driving force and can move horizontally along the crossbeams (313). Driven by the main lifting cylinders (312) and auxiliary lifting cylinders (315), the height travel of the outriggers (311) can be adjusted within a set range.

4. The gantry-type rail unloading and replacement system according to claim 3, characterized in that: The launching and retracting mechanism (32) includes a connecting beam (320), a base (321), a traveling trolley (322), a power system (323), a lifting column (324), a rotating device (325), a leveling mechanism (326), and a lifting drive mechanism (336); the base (321) is located at both ends of the connecting beam (320) along its length and is fixedly connected to the general-purpose flatbed cart (2); the traveling trolley (322) is located on the connecting beam (320); the power system (323 ... on the connecting beam (320) along its length and is fixedly connected to the general-purpose flatbed cart (2); the traveling trolley (322) is located on the connecting beam (320); the power system (323) is located on the connecting beam (320) along its length and is fixedly connected to the general-purpose flatbed cart (2); the traveling trolley (324) is located on the connecting beam (325); the power system (325) is located on the connecting beam (326); the traveling trolley (325) is located on the connecting beam (326); the power system (326) is located on the connecting beam (320 The lifting column (324) is placed on the traveling trolley (322), and the rotating device (325) is located on the top of the lifting column (324). The leveling mechanism (326) is located on the rotating device (325). The lifting column (324) adopts a two-stage guide column nested telescopic structure. The lifting drive mechanism (336) is located between the two-stage guide columns. The lifting operation of the lifting column (324) is realized through the telescopic action of the lifting drive mechanism (336).

5. The gantry-type rail unloading and replacement system according to claim 4, characterized in that: The base (321) is also provided with a fixing slot (327) for fixing the outriggers (311) of the gantry crane device (31) in the transportation state; during the placement of the gantry crane device (31), the lifting column (324) pushes the gantry crane device (31) out of the fixing slot (327) to avoid obstacles below and prevent interference and collision during rotation; the rotating device (325) is driven by a hydraulic motor to achieve rotation of the slewing bearing. When the gantry crane device (31) is lifted to the set height by the lifting column (324), the rotating device (325) rotates the gantry crane device (31) 90° to achieve the switch from transportation posture to working posture.

6. The gantry-type rail unloading and replacement system according to claim 4 or 5, characterized in that: The leveling mechanism (326) also includes a gantry crane take-up and drop slot (328), a mounting base (329), and a leveling drive mechanism (330). The gantry crane take-up and drop slot (328) is used to place the crossbeam (313) of the gantry crane device (31). The mounting base (329) is located on the top of the lifting column (324), and the top of the mounting base (329) is hinged to the bottom of the gantry crane take-up and drop slot (328). The leveling drive mechanism (330) is hinged to the ends of the gantry crane take-up and drop slot (328) and the mounting base (329) on the same side along the length direction. The leveling mechanism (326) realizes the tilt angle adjustment of the left and right sides within a set range through the leveling drive mechanism (330) to compensate for the inconsistent left and right heights of the frame plane of the general flatbed vehicle (2).

7. The gantry-type rail unloading and replacement system according to claim 4, characterized in that: The traveling trolley (32) includes a chain (331), a drive motor (332), a grooved guide rail (333), traveling wheels (334), and a sprocket (335). The grooved guide rail (333) is mounted on the connecting beam (320). The traveling trolley (32) cooperates with the grooved guide rail (333) through the traveling wheels (334). The drive motor (332) drives the sprocket (335) to mesh with the chain (331), thereby enabling the traveling trolley (32) to move longitudinally along the grooved guide rail (333). The traveling trolley (32) adjusts the position of the gantry crane device (31) during placement or compensates for the parking error of the railcar (1) during the gantry crane device (31) retrieval process through the drive motor (332).

8. The gantry-type rail unloading and replacement system according to claim 4, 5 or 7, characterized in that: The general-purpose flatbed vehicle (2) is equipped with several rail locking devices (5) along the line direction. The rail locking devices (5) are used to place, lock and transport new rails (4).

9. The gantry-type rail unloading and replacement system according to claim 8, characterized in that: During the replacement of the new rail (4), the rail locking device (5) is first unlocked, and then the gantry crane device (31) is lifted to the set height by the lifting action of the lifting mechanism (32). After that, it is rotated 90° so that the crossbeam (313) of the gantry crane device (31) is aligned with the direction of the sleeper (7). When it is determined that there is space to lower the gantry crane device (31) on both sides of the track (6), the outriggers (311) of the gantry crane device (31) are lowered to contact the ground to ensure that it is placed stably on the track (6). Then the lifting mechanism (32) is lowered to the initial position to complete the placement of the gantry crane device (31).

10. The gantry rail unloading and replacement system according to claim 4, 5, 7 or 9, characterized in that: Each set of rail loading and unloading devices (3) has a gantry crane device (31) and a take-up and put-down mechanism (32) that are operated individually to control various motions, so as to ensure that multiple sets of rail loading and unloading devices (3) can be carried out simultaneously by multiple people during construction operations; the lifting mechanism (314) of the gantry crane device (31) can be switched between local operation and centralized control, and the individual control or centralized control mode can be selected according to the site conditions.

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