Rail gas pressure welding machine

Abstract

To provide a rail gas pressure welding machine that is lighter and can be transported and installed by a small number of people. [Solution] A rail gas pressure welding machine that heats and pressurizes a pair of rails to be welded while they are clamped together comprises a fixed frame attached to one side of the pair of rails, a support frame located on the other side of the pair of rails and on which a pressurizing cylinder is detachably mounted, a plurality of guide means, one end of which is fixed to the fixed frame and the other end of which is fixed to the support frame, and a movable frame attached to the other side of the pair of rails, driven by the pressurizing cylinder and movable along the plurality of guide means, wherein the fixed frame, support frame and movable frame each consist of a pair of clamp members at the top, which are connected to each other by a connecting shaft and at the bottom, which can be installed on both sides of the pair of rails.

Description

Technical Field

[0001] The present invention relates to a rail gas pressure welding machine that heats and presses a pair of rails to be pressure-welded in a clamped state to perform pressure welding. Background Art

[0002] Conventionally, when a defective portion occurs in an existing railway rail, gas pressure welding is used to join the rail when cutting the rail at the defective portion and replacing it with a new rail. Gas pressure welding is a joining method in which rails to be joined are butted against each other, and while being pressed in the axial direction, the periphery of the butted portion is heated to a high temperature with a gas flame to obtain a predetermined amount of deformation and then joined.

[0003] A rail gas pressure welding machine of a type that is placed over a rail and used in such a gas pressure welding method is well known (Patent Document 1).

[0004] In the rail gas pressure welding machine described in Patent Document 1, a support frame to which a pressurizing cylinder is attached is disposed opposite to a fixed frame that clamps one rail to be joined and receives pressure, with a space therebetween in the longitudinal direction of the rails to be joined, and a moving frame driven by the pressurizing cylinder is installed inward on the support frame side. Each frame is assembled by a common guide shaft at three positions: both sides of the bottom portion and the top portion located above the rail.

[0005] Further, between the fixed frame and the moving frame, a burner case that supports a gas burner serving as a heating source for the joint portion is installed in a detachable manner that covers the three guide shafts from above. Clamping cylinders for clamping the rail are respectively attached to the fixed frame and the moving frame, and a push-out bit member for pushing out excess weld after joining is provided on the front surface of the moving frame.

[0006] Further, a small and lightweight rail base clamp type rail gas pressure welding machine that clamps and fixes to the base portion of a rail has been proposed (Patent Document 2).

[0007] The rail gas pressure welding machine described in Patent Document 2 comprises a fixed frame to which one rail to be pressure-welded is attached and fixed, a movable frame to which the other rail to be pressure-welded is attached and fixed, a compression movement tracking mechanism provided on the outside of the fixed frame, and a support member.

[0008] Furthermore, in recent years, progress has been made in developing gas pressure welding methods that can reduce the amount of compression during gas pressure welding and reduce oxidative inclusions even when the amount of compression is reduced. For example, a gas pressure welding method for rails has been proposed that can reduce oxidative inclusions even when the amount of compression during gas pressure welding is reduced (Patent Document 3). In this case, there is less excess material after pressure welding, and there is no need to remove it by hot shear with a special cutting tool, so the requirements for the structural strength of each frame are relaxed. [Prior art documents] [Patent Documents]

[0009] [Patent Document 1] Japanese Patent Application Publication No. 5-237669 [Patent Document 2] Japanese Patent Publication No. 2003-60937 [Patent Document 3] Japanese Patent Publication No. 2003-170075 [Overview of the project] [Problems that the invention aims to solve]

[0010] The rail gas pressure welding machine described in Patent Document 1 reduces unnecessary weight by making the thick-walled portion necessary to maintain structural strength in each frame, which accounts for a large proportion of the total weight of the welding machine, roughly in an inverted V shape, thereby reducing the overall weight from approximately 600 kg to about half of the conventional weight. However, when installing the device on the rail, it is necessary to transport it with a large number of people or with transport machinery such as a crane.

[0011] Furthermore, while the rail gas pressure welding machine described in Patent Document 2 is small and lightweight, it requires the device to be installed under the rails beforehand when welding the rails. Therefore, when welding rails on-site, it is necessary to remove the sleepers, gravel (crushed stone), or concrete materials under the rails and then lay them back down, which is time-consuming and labor-intensive.

[0012] Therefore, the objective of the present invention is to provide a rail gas pressure welding machine that is lighter and can be transported and installed by a small number of people.

[0013] Another object of the present invention is to provide a rail gas pressure welding machine that is lightweight and easy to install. [Means for solving the problem]

[0014] According to the present invention, a rail gas pressure welding machine that heats and pressurizes a pair of rails to be pressure welded while they are clamped together comprises a fixed frame attached to and fixed to one side of the pair of rails, a support frame located on the other side of the pair of rails and on which a pressurizing cylinder is detachably mounted, a plurality of guide means, one end of which is fixed to the fixed frame and the other end of which is fixed to the support frame, and a movable frame attached to and fixed to the other side of the pair of rails, driven by the pressurizing cylinder and movable along the plurality of guide means, wherein the fixed frame, support frame and movable frame each consist of a pair of clamp members, the upper part of which is connected to each other by a connecting shaft and the lower part of which can be installed on both sides of the pair of rails, respectively.

[0015] In a rail gas pressure welding machine, the fixed frame, support frame, and movable frame are each connected to each other at the top by a connecting shaft, and their lower parts consist of a pair of clamp members that can be installed on both sides of a pair of rails. The fixed frame and movable frame each have a detachable undershaft that connects the lower parts of their respective pairs of clamp members. By dividing each frame, which accounts for a large proportion of the overall weight of the welding machine, into a pair of clamp members, the portion of each frame above the rails consists only of the connecting part, resulting in a lighter machine that can be transported and installed by fewer people. This improves work efficiency. Furthermore, since the pressurizing cylinder is detachably attached to the support frame, it can be removed during transport and installation, further reducing weight and facilitating assembly.

[0016] Each of the fixed frame and the movable frame has a removable undershaft that connects the lower parts of their respective pairs of clamp members to each other. Preferably, the undershaft is inserted from below the pair of rails when the fixed frame and the movable frame are installed above the pair of rails, thereby connecting the pair of clamp members to each other. This ensures that the fixed frame and the movable frame can securely clamp the pair of rails to be pressed together. Furthermore, it eliminates the need to remove large quantities of sleepers, gravel (crushed stone), or concrete from under the rails, saving time and labor on removal and re-laying work, and improving efficiency.

[0017] Preferably, the undershaft has multiple engaging protrusions on one end, and is formed so that when inserted through the insertion hole of one clamp member and rotated by a predetermined angle, the multiple engaging protrusions engage with the engaging receiving portion of the other clamp member. This makes it easy to connect the lower parts of the pair of clamp members to each other when installing.

[0018] In both the fixed and movable frames, it is preferable that one clamping member has a reference-side chuck that contacts one side of each of the pair of rails, and the other clamping member has a detachable clamping cylinder that drives a movable chuck to contact and clamp the other side of each of the pair of rails. This allows the clamping cylinder to be removed when transporting or installing the rail gas pressure welding machine, resulting in a lighter weight and easier assembly. [Effects of the Invention]

[0019] According to the present invention, each of the fixed frame, support frame, and movable frame is connected to each other at the top by a connecting shaft, and its lower part consists of a pair of clamp members that can be installed on both sides of a pair of rails. By dividing each frame, which accounts for a large proportion of the overall weight of the welding machine, into a pair of clamp members, the portion of each frame above the rails consists only of the connecting part, making it lighter and allowing for transportation and installation by fewer people. Therefore, work efficiency can be improved.

[0020] Furthermore, since the pressurizing cylinder and clamping cylinder are detachable, they can be removed during transportation and installation, reducing weight and facilitating easy assembly.

[0021] Furthermore, each of the fixed frame and the movable frame has a removable undershaft that connects the lower parts of their respective pairs of clamping members to each other. The undershaft is inserted from below the pair of rails when the fixed frame and the movable frame are installed above the pair of rails, and is configured to connect their respective pairs of clamping members to each other. This ensures that the fixed frame and the movable frame can securely clamp the pair of rails to be pressed together. In addition, it eliminates the need to remove large amounts of sleepers, gravel (crushed stone), or concrete from under the rails, saving time and labor on removal and re-laying work, and improving efficiency. [Brief explanation of the drawing]

[0022] [Figure 1] It is a perspective view schematically showing the configuration of a rail gas pressure welding machine according to an embodiment of the present invention (viewed from the right side). [Figure 2] It is a perspective view schematically showing the configuration of the rail gas pressure welding machine according to the embodiment of Fig. 1 (viewed from the left side). [Figure 3] It is (A) a side view and (B) an end view viewed from the left side, schematically showing the configuration of a main body portion of the rail gas pressure welding machine according to the embodiment of Fig. 1. [Figure 4] It is a perspective view schematically showing the configuration and mounting state of a reference-side chuck of the rail gas pressure welding machine according to the embodiment of Fig. 1. [Figure 5] It is a perspective view schematically showing the configuration and mounting state of a spacer member of the rail gas pressure welding machine according to the embodiment of Fig. 1. [Figure 6] It is a perspective view schematically showing a state where the roller position of the rail gas pressure welding machine is adjusted according to the embodiment of Fig. 1. [Figure 7] It is a perspective view schematically showing a method of setting the rail gas pressure welding machine on a rail according to the embodiment of Fig. 1 (Step 1: placing on the rail). [Figure 8] It is a perspective view schematically showing a method of setting the rail gas pressure welding machine on a rail according to the embodiment of Fig. 1 (Step 2: inserting the undershaft). [Figure 9] It is a perspective view schematically showing a method of setting the rail gas pressure welding machine on a rail according to the embodiment of Fig. 1 (Step 3: mounting the reference-side chuck). [Figure 10] It is a perspective view schematically showing a method of setting the rail gas pressure welding machine on a rail according to the embodiment of Fig. 1 (Step 4: mounting the spacer member). [Figure 11] It is a perspective view schematically showing a method of setting the rail gas pressure welding machine on a rail according to the embodiment of Fig. 1 (Step 5: the mounting state of the reference-side chuck and the spacer member). [Figure 12]Figure 1 schematically shows the rail gas pressure welding machine in the embodiment being moved along the rail (A) a perspective view showing the movable state and (B) a view from the end face. [Figure 13] This diagram shows the state of the forces experienced when clamping in a conventional integrated frame and the frame of the present invention. [Figure 14] This figure shows other examples of undershaft and clamp member configurations. [Figure 15] The images show the undershaft being inserted from the right side of the clamp member (A) and from the left side of the clamp member (B). [Modes for carrying out the invention]

[0023] Hereinafter, an embodiment of the rail gas pressure welding machine according to the present invention will be described with reference to the figures. The rail gas pressure welding machine of this embodiment is a rail gas pressure welding machine that performs pressure welding of railway rails using the gas pressure welding method.

[0024] Figure 1 schematically shows the configuration of a rail gas pressure welding machine 100 for railway rails in one embodiment of the present invention, Figure 2 schematically shows the configuration of the rail gas pressure welding machine 100, and Figure 3 schematically shows the configuration of the main body of the rail gas pressure welding machine 100, with Figure 3(A) showing the configuration as seen from the front and Figure 3(B) showing the configuration as seen from the left side. Figure 4 schematically shows the configuration of the reference side chuck 13, and Figure 5 schematically shows the configuration of the spacer member S. Note that the reference side chuck 44 has the same configuration as the reference side chuck 13.

[0025] As shown in Figures 1 to 3, the rail gas pressure welding machine 100 of this embodiment includes a fixed frame 10 attached to and fixed to one side of a pair of rails, a support frame 20 located on the other side of the pair of rails, a plurality (four) of guide shafts 30 (corresponding to the "guide means" of the present invention) with one end fixed to the fixed frame 10 and the other end fixed to the support frame 20, a movable frame 40 attached to and fixed to the other side of the pair of rails and movable along the plurality of guide shafts 30, and a pair of pressurizing cylinders 50a and 50b detachably mounted on the support frame 20. The fixed frame 10 and the support frame 20 are arranged opposite each other with a gap in the longitudinal direction of the pair of rails to be joined. The movable frame 40, driven by the pressurizing cylinders 50a and 50b, is installed on the inner side of the support frame 20, and these fixed frame 10, support frame 20 and movable frame 40 are assembled by the plurality (four) of guide shafts 30.

[0026] The fixing frame 10 clamps one of the rails to be joined and receives pressure. The fixing frame 10 is composed of a pair of clamp members 10a and 10b, which can be installed on both sides of the rail, with the upper part of the frame 10 being connected to the other by a connecting shaft 11. The fixing frame 10 also has a detachable undershaft 12 that connects the lower parts of the pair of clamp members 10a and 10b. This undershaft 12 is inserted from below the rail when the fixing frame 10 is installed from above the rail, and is configured to connect the pair of clamp members 10a and 10b to each other. The undershaft 12 also has a plurality (for example, three) of engaging protrusions 12a on one end, and is formed to engage with the engaging receiving portion 10c of the other clamp member 10b by inserting it through the insertion hole of one clamp member 10a and rotating it by a predetermined angle (see Figure 8 described later). The engaging receiving portion 10c is formed inside the insertion hole on the clamp member 10b side.

[0027] Furthermore, in the fixed frame 10, one clamp member 10b has a reference-side chuck 13 that abuts against one side of the rail, and the other clamp member 10a has a detachable clamping cylinder 15 that drives the movable chuck 14 to abut against the other side of the rail and clamp it. Here, the reference-side chuck 13 also functions as a centering mechanism for the pair of rails. The movable chuck 14 is fixed to the tip of a back plate 14a, which acts as a reinforcing member when pressurized, and the back plate 14a is mounted so as to be slidable in conjunction with the movable chuck 14.

[0028] As shown in Figure 4, the reference-side chuck 13 is formed in a wedge shape with an inclined surface, is detachably attached to the clamp member 10b, and is configured to allow adjustment of its insertion position to match the gap between the clamp member 10b of the fixed frame 10 and one side of the rail. In this embodiment, the reference-side chuck 13 consists of two reference-side chuck divisions 13A and 13B arranged vertically. The inclined surfaces of the reference-side chuck divisions 13A and 13B are mounting surfaces and have engaging projections 13a. On the other hand, the mounting surface on the clamp member 10b side consists of an inclined surface C and an engaging groove D provided on the inclined surface C. When attaching the reference-side chuck divisions 13A and 13B to the clamp member 10b, they are attached by sliding the engaging projections 13a on the mounting surface along the engaging groove D on the clamp member 10b side. After attachment, the surfaces of the reference-side chuck divisions 13A and 13B (the surfaces that contact the rail's side) are parallel to the rail's side. Furthermore, the base end sides of the reference-side chuck divisions 13A and 13B have insertion position restricting portions 13b that restrict the insertion position when they are attached to the clamp member 10b of the fixed frame 10. These insertion position restricting portions 13b have insertion recesses 13c into which any of a plurality of spacer members S having different thicknesses for adjusting the insertion position can be inserted. By providing the insertion position restricting portions 13b, clamp displacement during pressurization can be prevented.

[0029] As shown in Figure 5, the spacer member S has a spacer portion Sx that restricts the insertion position of the reference-side chuck segments 13A and 13B, and an insertion projection Sy that can be inserted into the insertion recess 13c of the insertion position restricting portion 13b. The spacer member S restricts the insertion position of the reference-side chuck segments 13A and 13B and also has a function to prevent the reference-side chuck segments 13A and 13B from coming loose. In this embodiment, for example, the spacer member S has six types of spacer portions Sx with thicknesses of 0 mm, 2 mm, 4 mm, 6 mm, 8 mm, and 10 mm. The spacer member S is also held by a spacer holding portion 10bs provided on the fixed frame 10.

[0030] Furthermore, the fixed frame 10 has rollers 16 that can travel along the upper surface of the rail, and the fixed frame 10 rests on the upper surface of the rail via the rollers 16. The fixed frame 10 further includes a roller position adjustment mechanism 17 for adjusting the vertical position of the rollers 16. This roller position adjustment mechanism 17 has a plurality of clamp positioning parts 17a, 17b corresponding to the height of the rail, a travel positioning part 17c, and a lever 18. The lever 18 is configured to fit and position the clamp positioning parts 17a, 17b and the travel positioning part 17c.

[0031] The support frame 20 is located on the other rail of the pair of rails to be joined, and is configured to allow a pair of pressurizing cylinders 50a and 50b to be detachably mounted. The upper part of the support frame 20 is connected to each other by a connecting shaft 21, and the lower part consists of a pair of clamp members 20a and 20b that can be installed on both sides of the rail R2, respectively. One end of a guide shaft 30 is attached to the upper and lower parts of each of the pair of clamp members 20a and 20b. Each of the pair of clamp members 20a and 20b is provided with mounting holes 22a and 22b for mounting the pressurizing cylinders 50a and 50b, and the mounting holes 22a and 22b have engaging parts 23a and 23b that engage with and prevent the mounted pressurizing cylinders 50a and 50b by rotation after insertion. The pressurizing cylinders 50a and 50b can be mounted by inserting them into the mounting holes 22a and 22b from the outside of each of the clamp members 20a and 20b, rotating them by a predetermined angle, and engaging the engaging parts.

[0032] Furthermore, the support frame 20 has rollers 26 that can travel along the upper surface of the rail, and the support frame 20 rests on the upper surface of the rail via the rollers 26. The support frame 20 further includes a roller position adjustment mechanism 27 for adjusting the vertical position of the rollers 26. This roller position adjustment mechanism 27 has a plurality of clamp positioning parts 27a, 27b corresponding to the height of the rail, a travel positioning part 27c, and a lever 28. The lever 28 is configured to fit and position the clamp positioning parts 27a, 27b and the travel positioning part 27c.

[0033] The guide shafts 30 are made of metal rods, and in this embodiment, the fixed frame 10, the support frame 20, and the movable frame 40 are assembled using four parallel-arranged guide shafts 30. One end of each guide shaft 30 is inserted and fixed through the upper and lower insertion holes of a pair of clamp members 10a and 10b of the fixed frame 10, respectively. The other end of each guide shaft 30 is inserted and fixed through the upper and lower insertion holes of a pair of clamp members 20a and 20b of the support frame 20, respectively.

[0034] The movable frame 40 is positioned between the fixed frame 10 and the support frame 20, on the support frame 20 side, and is attached and fixed to the other rail. It is driven by pressurizing cylinders 50a and 50b and is configured to move along four guide shafts 30. The movable frame 40 consists of a pair of clamp members 40a and 40b, which can be installed on either side of the rail, with their upper parts connected by a connecting shaft 41. The movable frame 40 also has a detachable undershaft 42 that connects the lower parts of the pair of clamp members 40a and 40b. This undershaft 42 is inserted from below the rail when the movable frame 40 is installed from above the rail, and is configured to connect the pair of clamp members 40a and 40b to each other. Furthermore, the undershaft 42 has a plurality (for example, three) of engaging protrusions 42a on one end, and is formed to engage with the engaging receiving portion 40c of the other clamp member 40b by inserting it through the insertion hole of one clamp member 40a and rotating it by a predetermined angle (see Figure 8, described later). The engaging receiving portion 40c is formed inside the insertion hole on the clamp member 40b side. The pair of clamp members 40a and 40b have joint blocks 43a and 43b on their rear surfaces (the surfaces facing the support frame 20) to which the rods 51a and 51b of the pressurizing cylinders 50a and 50b are connected.

[0035] Furthermore, in the movable frame 40, one clamping member 40b has a reference-side chuck 44 that abuts against one side of the rail, and the other clamping member 40a has a detachable clamping cylinder 46 that drives the movable chuck 45 to abut against the other side of the rail and clamp it. Here, the reference-side chuck 44 also functions as a centering mechanism for the pair of rails. The movable chuck 45 is fixed to the tip of a back plate 45a, which acts as a reinforcing member when pressurized, and the back plate 45a is mounted so as to be slidable in conjunction with the movable chuck 45.

[0036] The reference-side chuck 44 is formed in a wedge shape with an inclined surface, is detachably attached to the clamp member 40b, and is configured to allow adjustment of its insertion position to match the gap between the clamp member 40b of the movable frame 40 and one side of the rail. In this embodiment, the reference-side chuck 44 is composed of two reference-side chuck divisions 44A and 44B arranged vertically (see Figure 4). The inclined surfaces of the reference-side chuck divisions 44A and 44B are mounting surfaces and have engaging projections 44a. On the other hand, the mounting surface on the clamp member 40b side is composed of an inclined surface C and an engaging groove D provided on the inclined surface C. When mounting the reference-side chuck divisions 44A and 44B to the clamp member 40b, they are mounted by sliding the engaging projections 44a on the mounting surface along the engaging groove D on the clamp member 40b side. After mounting, the surfaces of the reference-side chuck divisions 44A and 44B (the surfaces that contact the side of the rail) are parallel to the side of the rail. Furthermore, the base end of the reference-side chuck divisions 44A and 44B has an insertion position restricting portion 44b that restricts the insertion position when they are attached to the clamp member 40b of the movable frame 40. This insertion position restricting portion 44b has an insertion recess 44c into which one of a plurality of spacer members S having different thicknesses for adjusting the insertion position can be inserted. By providing the insertion position restricting portion 44b, clamp misalignment during pressurization can be prevented. As shown in Figure 5, the spacer member S has a spacer portion Sx that restricts the insertion position of the reference-side chuck divisions 44A and 44B, and an insertion projection Sy that can be inserted into the insertion recess 44c of the insertion position restricting portion 44b, thereby restricting the insertion position of the reference-side chuck divisions 44A and 44B and having a function to prevent the reference-side chuck divisions 44A and 44B from coming off. In this embodiment, for example, the spacer member S has six types of spacer portions Sx with thicknesses of 0 mm, 2 mm, 4 mm, 6 mm, 8 mm, and 10 mm. Furthermore, the spacer member S is held in place by a spacer holding portion 40bs provided on the movable frame 40.

[0037] The pressurizing cylinders 50a and 50b are mounted on the support frame 20 and are pressurizing means for driving the movable frame 40 and pressing a pair of rails together. The rods 51a and 51b of the pressurizing cylinders 50a and 50b are connected to joint blocks 43a and 43b which are attached to the rear surface of the movable frame 40.

[0038] The burner case, which supports the gas burner that serves as the heat source for the joint, is installed by placing it over the four guide shafts 30 from above. It can be transported separately from the main body of the rail gas pressure welding machine 100.

[0039] The following describes how to install and press-weld the rail gas pressure welding machine 100 of this embodiment onto a pair of rails R1 and R2 that are to be joined together, with reference to Figures 6 to 12.

[0040] When installing the rail gas pressure welding machine 100 on rails R1 and R2, first, as shown in Figure 6, the lever 18 is fitted into the corresponding clamp positioning section 17a or 17b, and the lever 28 is fitted into the corresponding clamp positioning section 27a or 27b, according to the type of rails R1 and R2 to be joined (50N rail or 60K rail), and the vertical positions of the rollers 16 and 46 are adjusted. Figure 6(A) shows the lever 18 in the clamp positioning section 17a corresponding to the 60K rail, Figure 6(B) shows the lever 18 in the clamp positioning section 17b corresponding to the 50N rail, and Figure 6(C) shows the lever 18 in the running positioning section 17c. The same applies to the other lever 28.

[0041] Next, as shown in Figure 7, with the joining surfaces R0 of the pair of rails R1 and R2 to be joined together, the main body of the rail gas welding machine 100 is placed on the rails R1 and R2. For example, with the lever 18 fitted into the clamp positioning part 17a corresponding to the 60K rail, the main body of the rail gas welding machine 100 is placed on top of the rails R1 and R2, and the rollers 16 and 26 are set to contact the upper surfaces of the rails R1 and R2, respectively. In this embodiment, for example, the fixed frame 10 is installed on the rail R1 side and the support frame 20 is positioned on the rail R2 side.

[0042] Next, as shown in Figure 7, the clamping cylinder 15 is attached to the clamping member 10a of the fixed frame 10, and the clamping cylinder 46 is attached to the clamping member 40a of the movable frame 40. In addition, the pressurizing cylinders 50a and 50b are attached to the support frame 20, and the rods 51a and 51b of the pressurizing cylinders 50a and 50b are connected to the joint blocks 43a and 43b attached to the rear surface of the movable frame 40.

[0043] Next, as shown in Figure 8, the undershafts 12 and 42 are inserted from below the rails R1 and R2, respectively, connecting the pair of clamp members 10a and 10b and the pair of clamp members 40a and 40b to each other.

[0044] Next, as shown in Figures 9 and 11(A), the reference-side chuck segments 13A and 13B of the fixed frame 10 are inserted between the clamp member 10b of the fixed frame 10 and one side of the rail R1. The reference-side chuck segments 44A and 44B of the movable frame 40 are inserted between the clamp member 40b of the movable frame 40 and one side of the rail R2. Then, as shown in Figures 10 and 11(B), a spacer member S selected from a plurality of spacer members S of different thicknesses is inserted into the insertion position regulating portion 13b of the reference-side chuck segments 13A and 13B, and also into the insertion position regulating portion 44b of the reference-side chuck segments 44A and 44B. This allows the insertion positions of the reference-side chuck segments 13A and 13B and 44A and 44B to be adjusted. The surfaces (rail-contacting surfaces) of the reference-side chuck segments 13A, 13B and 44A, 44B can be brought into close contact with one of the sides of rail R1 and rail R2.

[0045] Next, the clamping cylinder 15 drives the movable chuck 14, bringing it into contact with the other side of rail R1 and clamping rail R1. Then, the clamping cylinder 46 drives the movable chuck 45, bringing it into contact with the other side of rail R2 and clamping rail R2. This completes the mounting of the rail gas pressure welding machine 100 to rails R1 and R2.

[0046] Next, a burner case (not shown) is placed over the four guide shafts 30 from above. A gas burner, which is the heat source for the joint, is then installed in the burner case.

[0047] When pressing a pair of rails R1 and R2 together, heating is performed with a gas burner, and the movable frame 40 is driven by pressurizing cylinders 50a and 50b to pressurize the abutting portion of rails R1 and R2. The entire circumference is then heated by an oxygen-acetylene flame from the gas burner to perform the pressing. After pressing, the excess material around the joint surface R0 is removed using a grinder or the like. Alternatively, a punching tool may be provided on the front of the movable frame 40 to push out the excess material after joining.

[0048] Furthermore, after welding is completed at one location, when moving the rail gas welding machine 100 along rail R1 or R2 to another welding position, or when performing adjustment work on the rail joint while it is still hot, or when moving the rail gas welding machine 100 away from the joint, as shown in Figure 12, first, the clamping cylinders 15 and 46 of the fixed frame 10 and the movable frame 40 are driven in reverse to release the clamps from the movable chucks 14 and 45 side. Next, the spacer member S, the reference side chuck divisions 13A and 13B, and the reference side chuck divisions 44A and 44B are removed. Next, the undershafts 12 and 42 are removed, respectively. Next, the lever 18 on the fixed frame 10 side is fitted into the travel positioning section 17c and positioned (see Figure 6(C)). Similarly, the lever 28 on the support frame 20 side is fitted into the travel positioning section 27c and positioned. As a result, the lower ends of the fixed frame 10, support frame 20, and movable frame 40 of the rail gas pressure welding machine 100 rise above the bottom surface of rails R1 and R2, allowing it to move without interfering with the sleepers (see Figure 12(B)). Then, when the rail gas pressure welding machine 100 is pushed in either direction of rails R1 or R2 (in the direction of the arrow in Figure 12(A)), the rollers 16 and 46 travel on the upper surface of rails R1 and R2, thereby moving the rail gas pressure welding machine 100.

[0049] As described above, the rail gas pressure welding machine 100 of this embodiment includes a fixed frame 10 attached to and fixed to one side of a pair of rails to be joined together, a support frame 20 located on the other side of the pair of rails, a plurality of guide shafts 30 with one end fixed to the fixed frame 10 and the other end fixed to the support frame 20, a movable frame 40 attached to and fixed to the other side of the pair of rails and movable along the plurality of guide shafts 30, and a pair of pressurizing cylinders 50a, 50b detachably mounted on the support frame 20. The fixed frame 10, the support frame 20, and the movable frame 40 each consist of a pair of clamp members 10a, 10b, 20a, 20b, and 40a, 40b at the top, which are connected to each other by connecting shafts 11, 21, and 41, and at the bottom, which can be installed on both sides of the pair of rails R1, R2, respectively.

[0050] This design divides each frame, which accounts for a large proportion of the overall weight of the rail gas pressure welding machine 100, into a pair of clamping members. As a result, the portion of each frame above the rail consists only of the connecting part, making it lighter and allowing for transportation and installation by fewer people. Therefore, work efficiency can be improved.

[0051] Furthermore, since the pressurizing cylinders 50a and 50b and the clamping cylinders 15 and 46 are detachable, they can be removed during transportation and installation, resulting in weight reduction and easier assembly. Additionally, by making the clamping cylinders 15 and 46 detachable, they can be removed when transporting and installing the rail gas pressure welding machine on the rail, further reducing weight and making assembly easier.

[0052] Furthermore, each of the fixed frame 10 and the movable frame 40 has detachable undershafts 12 and 42 that connect the lower parts of their respective pairs of clamp members 10a, 10b and 40a, 40b. The undershafts 12 and 42 are inserted from below the pair of rails R1, R2 when the fixed frame 10 and the movable frame 40 are installed from above the pair of rails R1, R2, and are configured to connect their respective pairs of clamp members. As a result, the fixed frame 10 and the movable frame 40 can reliably clamp the pair of rails R1, R2 to be pressed together. Moreover, when clamping, as shown in Figure 13, the lower part of a conventional integrated frame deforms outward and excessive stress is concentrated on the upper part (see Figure 13(A)), requiring a robust shape. In contrast, the rail gas pressure welding machine 100 of the present invention receives outward force uniformly on the upper and lower parts of the frame (see Figure 13(B)), allowing for a thinner shape and reducing the weight of the frame. Furthermore, in the case of the rail gas pressure welding machine 100 of the present invention, there is no need to remove large quantities of sleepers, gravel (crushed stone), or concrete materials from under the rails, saving time and labor in removal and re-laying work, and improving efficiency.

[0053] Furthermore, each of the reference-side chucks 13 and 44 is formed in a wedge shape with an inclined surface, and is detachably attached to the fixed frame 10 and the movable frame 40, respectively. The insertion position can be adjusted to match the gap between each of the fixed frame 10 and the movable frame 40 and one of the sides of the pair of rails R1 and R2, thus allowing for easy adjustment of the abutting position between the joint surfaces of rails R1 and R2. Additionally, each of the reference-side chucks 13 and 44 is composed of two vertically aligned reference-side chuck divisions 13A, 13B and 44A, 44B. By adjusting the insertion positions of the two reference-side chuck divisions 13A, 13B and 44A, 44B, the gap caused by the inclination between the fixed frame 10 and the movable frame 40 and the rails R1 and R2 can be filled, thus accommodating misalignment in the torsional direction of the rails. Therefore, alignment of the pair of rails R1 and R2 to be pressed together is easily achieved. Furthermore, clamp misalignment during pressurization can be prevented, ensuring reliable clamping of rails R1 and R2.

[0054] Furthermore, each of the fixed frame 10 and the support frame 20 has rollers 16 and 26 that can travel along the upper surfaces of a pair of rails R1 and R2. Since the rail gas pressure welding machine 100 is mounted on the upper surfaces of the pair of rails R1 and R2 via the rollers 16 and 26, when moving the rail gas pressure welding machine 100 to another welding position on rail R1 or R2 after welding at one location is completed, the rail gas pressure welding machine 100 can be moved along rail R1 or R2 via the rollers 16 and 26 to the other welding position. Therefore, there is no need to move the rail gas pressure welding machine 100 using transport machinery such as cranes. In other words, the rail gas pressure welding machine 100 can be easily moved.

[0055] In the rail gas pressure welding machine 100 of the above-described embodiment, the undershafts 12 and 42 were described as being inserted from one of the clamp members 10b and 40b sides, but the present invention is not limited to this. For example, as shown in the modified example in Figure 14, they may be inserted from either side of both clamp members.

[0056] Figure 14 shows another configuration example of the undershaft and clamp member. As shown in Figure 14, the undershaft 12A (42A) has a plurality of engaging protrusions 12a on one end. In addition, the clamp members 10a and 10b of the fixed frame 10A and the clamp members 40a and 40b of the movable frame 40A are each provided with engaging receiving portions 10c (40c) of the same shape.

[0057] In this case, the undershaft 12A (42A) is provided with an operating handle H for rotating it. It also includes an end plate K and a locking pin P for maintaining the locked state of the undershafts 12A and 42A. By inserting the locking pin P, the locked state of the undershafts 12A and 42A can be securely maintained.

[0058] Figure 15 shows the state when the undershaft 12A (42A) is installed. Figure (A) shows the state when inserted from the clamp member 10a (40a) side, and (B) shows the state when inserted from the clamp member 10b (40b) side. As shown in Figure 15, after insertion, the end plate K and lock pin P are attached to the tip side of the undershaft 12A (42A) and fixed in place. In this case, the tip of the lock pin P is inserted into the recess 12b (42b) formed on the outer circumference of the engaging projection 12a (42a) of the undershaft 12A (42A). This allows the undershaft 12A (42A) to be inserted from either side of the clamp members, improving work efficiency. Furthermore, it prevents the clamp from loosening due to the rotation of the undershaft 12A (42A) during pressure welding.

[0059] Furthermore, although the rail gas pressure welding machine 100 of the above embodiment was described in which a fixed frame 10, a support frame 20, and a movable frame 40 are assembled using four guide shafts 30, the present invention is not limited to this. For example, three guide shafts may be used. In this case, a common guide shaft is used at the top of each frame, and each frame becomes approximately an inverted V shape.

[0060] Furthermore, in the rail gas pressure welding machine 100 of the above-described embodiment, an example was described in which each of the reference side chucks 13 and 44 is composed of two reference side chuck divisions 13A, 13B and 44A, 44B arranged in the vertical direction, but the present invention is not limited thereto. The reference side chuck may be composed of a single integrated chuck, or it may be composed of three reference side chuck divisions arranged in the vertical direction.

[0061] Furthermore, in the rail gas pressure welding machine 100 of the above-described embodiment, the roller position adjustment mechanism 17 of the fixed frame 10 has a plurality of clamp positioning parts 17a, 17b corresponding to the rail height, a running positioning part 17c, and a lever 18, and the roller position adjustment mechanism 27 of the support frame 20 has a plurality of clamp positioning parts 27a, 27b corresponding to the rail height, a running positioning part 27c, and a lever 28. However, the present invention is not limited to this. Other roller position adjustment mechanisms may be used.

[0062] Furthermore, although an example using a gas burner as a heat source in the rail gas pressure welding machine 100 of the above-described embodiment has been explained, the present invention is not limited thereto. The present invention can also be applied, for example, to a flash butt welding machine that uses the resistance heating of the material to be welded as a heat source.

[0063] The embodiments described above are all illustrative and not limiting, and the present invention can be implemented in various other modified and altered forms. Accordingly, the scope of the present invention is defined solely by the claims and their equivalents. [Explanation of symbols]

[0064] 10, 10A Fixed Frame 10a, 10b Clamp members 10bs Spacer retaining part 10c Engagement receiving part 11 Connecting shaft 12, 12A Undershaft 12a Engagement protrusion 12b Recessed area 13. Reference side chuck 13A, 13B Reference side chuck split parts 13a Engaging projection 13b Insertion position regulating section 13c Insertion recess 14. Movable chuck 14a Backplate 15 Clamping Cylinder 16 Laura 17a, 17b Clamp positioning section 17c Travel positioning section 18 Leva 20 Support Frame 20a, 20b Clamp members 21 Connecting shaft 22a, 22b Mounting holes 23a, 23b engaging part 26 Laura 27a, 27b Clamp positioning section 27c Travel positioning section 28 Leva 30 Guide shaft (guide means) 40, 40A Mobile Frame 40a, 40b Clamp members 40bs Spacer retaining part 40c Engagement receiving part 41 Connecting shaft 42, 42A Undershaft 42a Engagement protrusion 42b Recessed area 43a, 43b Joint Blocks 44 Reference side chuck 44A, 44B Reference side chuck split parts 44a Engagement protrusion 44b Insertion position regulating section 44c Insertion recess 45 Movable chuck 45a Backplate 46 Clamp Cylinder 50a, 50b Pressurizing Cylinders 51a, 51b rods 100 Rail Gas Pressure Welding Machine C Inclined surface D Engagement groove H Operating handle K end plate P Lock Pin R0 joint surface R1, R2 rails S Spacer Member Sx Spacer Section Sy insertion convex part

Claims

1. In a rail gas pressure welding machine that heats and pressurizes a pair of rails to be welded together while they are clamped, A fixing frame attached to and secured to one of the pair of rails, A support frame located on the other side of the pair of rails, to which a pressurizing cylinder is detachably mounted, A plurality of guide means, one end of which is fixed to the fixed frame and the other end of which is fixed to the support frame, A movable frame is attached and fixed to the other of the pair of rails, driven by the pressurizing cylinder, and movable along the plurality of guide means, A rail gas pressure welding machine characterized in that each of the fixed frame, the support frame, and the movable frame has an upper part connected to one another by a connecting shaft, and a lower part consisting of a pair of clamp members that can be installed on both sides of the pair of rails, respectively.

2. Each of the fixed frame and the movable frame has a detachable undershaft that connects the lower parts of the respective pair of clamp members to each other. The rail gas pressure welding machine according to claim 1, characterized in that the undershaft is inserted from below the pair of rails when the fixed frame and the movable frame are installed from above the pair of rails, and is configured to connect the pair of clamp members to each other.

3. The rail gas pressure welding machine according to claim 2, characterized in that the undershaft has a plurality of engaging protrusions on one end, and is formed so that when inserted through the insertion hole of one clamp member and rotated by a predetermined angle, the plurality of engaging protrusions engage with the engaging receiving portion of the other clamp member.

4. The rail gas pressure welding machine according to claim 1 or 2, characterized in that, in the fixed frame and the movable frame, one clamping member has a reference-side chuck that abuts against one side of each of the pair of rails, and the other clamping member has a detachable clamping cylinder that drives a movable chuck to abut against the other side of each of the pair of rails and clamp them.

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