EP1473409A1 - Method and device for treating sleepers - Google Patents

Abstract

To maintain and repair concrete railway track sleepers, the groups of sleepers are separated from the rails. In an automated process, the separated sleepers are lifted by a crane (23) from a transport vehicle (21) or intermediate storage to be transferred to a conveyor and storage and feed system (24). The system is a workstation on a rail-mounted vehicle or a static installation linked to a high pressure water system where, in a number of modules and preferably two modules, the dowels (5) are removed and the sleepers (11) are cleaned of dirt. The sleepers move on to a dowel module (34), where fresh dowels are inserted. A second crane (27) transfers the restored sleepers to a transport vehicle (35) or an intermediate storage. The assembly is a rake with a coupled high pressure module (30) and a current supply unit (29).

Description

The invention relates to a method and an apparatus for refurbishing parts the substructure of rail-based means of transport, in particular of Thresholds, which are preferably made of concrete. With a corresponding logistics concept "Just-in-time processing" can be implemented.

Concrete sleepers are separated in the course of track conversions or other measures, dismantled in groups or as part of the track yokes, transported away and / or filed next to track systems (DE-PS 44 21 662 C2, AT 359 537).

It is common for concrete sleepers to be detached from the rails, then individually or assessed in groups and no longer usable concrete sleepers (approx. 20 - 30%) are disposed of and disposed of and the remaining 70 - 80% can be worked up.

These will work in a few quasi-central locations, such as in building yards carried out and thereby considerable expenses for the delivery to these Places and the subsequent transport for reuse.

It is known that especially at construction sites on which not complete tracks, but Concrete sleepers can be replaced individually or in groups, the removed Concrete sleepers due to considerable logistics expenditure over long periods remain next to the tracks so that they can be reused over long periods are not available and therefore tie up capital avoidably.

The dowels contained in the sleepers are made using mechanical methods such as for example by drilling out and then manually removing dowel residues freed. The concrete sleepers are then manually pushed through, for example Hit in with new plastic dowels.

The entire process for the processing of concrete sleepers poses in particular because the considerable transport / logistics expenses neither effective nor professional or economic solution.

The use of high pressure water has been used for renovation and cleaning for years of concrete and other objects known and classified as state of the art.

The object of the invention is to develop a system for processing sleepers, preferably made of concrete, which consists of different modules that can be used both stationary and mobile.
This is achieved according to the invention by claims 1-17, the system consisting of a known rail-driven high-pressure water system (PLC), a coupled reprocessing system according to the invention and a likewise coupled conveyor, storage and loading system according to the invention, in that the conveyor, Bridge crane in the storage and loading system picks up the concrete sleepers individually or in groups from a standard sleepers transport vehicle standing on the neighboring track or from ground-level storage locations, places them lengthways or crossways on the wagon, and any rail fastenings that are still there are freed from the concrete sleepers. Concrete sleepers prepared in this way are fed to the cycle method in layers or individually by a hoist, for example a gantry crane on a loading device, consisting essentially of a pallet and a conveyor system, with one layer preferably consisting of five concrete sleepers arranged at an equal distance from one another.

The loading device largely transports the threshold group into the encapsulated debugging module, in which preferably at least two parallel high pressure lances are located, which according to the Hole course of the respective concrete sleeper type are inclined can, the pair of lances transverse to the conveying direction of the sleeper layer gradually remove at least two dowels in each threshold. With an inspection component consisting essentially of one preferably endoscopic camera, inside the deblocking module, the quality of the hole exposed by the high pressure water.

The suction system in the rail-driven high-pressure water system (PLC) generates a via appropriate suction lines in the deblocking module Vacuum, whereby the water mist is sucked off and a Malfunction of the inspection components is excluded. The accruing contaminated with remnants of plastic dowels and other substances Water is collected in a tub below the deblocking module.

Another conveyor device transports the pallet with the debugged Thresholds to the subsequent cleaning module, in which the thresholds are washed using a further, preferably high-pressure pump, the water from the drip pan below the deblocking module removed, filtered and arranged over all of the thresholds Nozzles are used to wash the sleepers. The use and contaminated Wash water becomes rail-drivable via a dirty water pump High pressure water system (SPS) promoted and in the existing two-stage Filter system, consisting of coarse filters and ultra-fine filters, cleaned in combination tank also located there temporarily and for one Reuse provided in the cleaning module.

The suction system in the rail-driven high-pressure water system (PLC) generated for example via side channel compressors and corresponding Suction lines also create a negative pressure in the cleaning module the resulting water mist is extracted and a trouble-free condition assessment the cleaned sleepers using one or more video cameras is possible.

Another conveyor transports the cleaned sleepers according to the cycle to the subsequent dowel module, in which it is initially visual and / or the quality of the sleepers before re-dowelling is subject to technical assessment. Thresholds not suitable for further use are marked and at the end of the reprocessing process using a Crane removed from the clock and for later disposal in one storage rack located below the rail vehicle or immediately disposed of locally.

After completion of the assessment, new anchors are preferably used in pairs pressed into the sleepers and, if necessary, the holes beforehand / filled with a filler at the same time. The dowels are made in the dowel module magazines located to the hole in the threshold, there by means of a Gripping device positioned and by a stamp that over a guide mandrel has, pressed into the bore.

Another conveyor transports the finished concrete sleepers under an on-board slewing crane, which the sleepers to Removal by means of a standard in the neighboring track Threshold transport vehicle or at ground level for immediate local reuse stores.

All units of the processing system and the conveyor, storage and Feeding systems are operated electrically and are powered by the generator the rail-driven high pressure water system (PLC) with energy provided. The entire system is monitored and controlled from the control room of the PLC controlled. In parallel, the control is directly from the respective module or crane off possible.

The rail-driven high-pressure water system (PLC), the reprocessing system and the conveyor, storage and loading system are among each other via flexible hose lines and with the necessary electrical Lines connected.

embodiment

The invention will be explained in more detail below using an exemplary embodiment become.

• Figur 1 Darstellung des Wasserverfahrens
• Figur 2 Darstellung des Absaugverfahrens
• Figur 3 Gesamtansicht des Betonschwellen-Aufbereitungssystems
• Figur 4 Aufsicht des Betonschwellen-Aufbereitungssystems (Anlieferung der Betonschwellen per Schienenfahrzeug)
• Figur 5 Aufsicht des Betonschwellen-Aufbereitungssystems (Aufnahme der Betonschwellen von ebenerdiger Lagerstelle)
• Figur 6 Betonschwellenaufbereitungszug

Show:

• Figure 1 representation of the water process
• Figure 2 Representation of the suction process
• Figure 3 General view of the concrete sleeper preparation system
• Figure 4 Supervision of the concrete sleeper preparation system (delivery of the concrete sleeper by rail vehicle)
• Figure 5 Supervision of the concrete sleeper preparation system (picking up the concrete sleeper from the ground-level storage location)
• Figure 6 Concrete sleeper preparation train

In its entirety there is the method and the device for mobile or stationary Refurbishment of concrete sleepers from a rail-driven high-pressure water system (SPS), a conveyor, storage and loading system and a reprocessing system, the individual modules also for stationary Can be put together to form a system.

The vehicles are mechanically and electrically separable. Electrical connections are all power supply and all control and regulation lines. To the mechanical connections include all piping and hose systems that are used for the transport of process water and suction air are determined and all elements that enable coupling.

The critical area of the connections lies between the vehicles (buffer area), since there are movements around the longitudinal and transverse axes of the connecting lines when driving occur. All lines are laid flexibly and protected to avoid damage during exclude the trip.

The table below shows the connection of the individual modules in the network.

The process water is from the fresh water area of the combi tank (1) via a Feed pump (2) pumped to the module of the maximum pressure unit (3). The maximum pressure pump, driven by a diesel engine (4), promotes the process water Desired pressure to the deblocking module (5), from there by means of the cross portal (6) to get the high pressure lances (7). The dissolved by the high pressure water and removed dowels go together with this into a collecting and filter container (8) below the module. After filtration, the water passes through an intermediate container (9) and via the feed and pre-pressure pump (10) to the cleaning module (11) and here to the cleaning nozzle assembly (13) and further to the cleaning nozzles. pump (14) conveys the dirty water into a separation tank with the coarse filters (15) in from which the coarse materials> 350 µm are separated out. Via the PLC-internal sewage pump (16) the water passes through the fine filter (17), for example, to < 10 µm grain size cleaned, to the process water area (18) of the combination tank (1).

The water in the intermediate tank is conveyed by a suction-pressure pump (36) (9) for further cleaning tasks in the cleaning module (11). A corresponding Regulation ensures that the water in the cleaning module (11) is sufficient Has quality so that the high pressure pump (12) is not damaged.

The water mist created in both the deblocking module (5) and in the cleaning module (11) is by the PLC internal suction system, consisting of two side channel compressors (20) and the negative pressure area of the separation tank (15), in which also possibly Impurities still contained in the water mist via a hydrocyclone is separated from the suction air.

The concrete sleepers to be processed are either above standard Threshold transport vehicle (21) or at ground level / storage locations (22) Available. From these positions, the sleepers are either stacked or sleeper row by means of overhead crane (23) on the conveyor, storage and Loading system (24) loaded and with it individually or in layers on the loading device (25) on which the sleepers in the for the further Process steps are brought apart and fixed. Other funding institutions (26) transport the sleepers through the plant in cycles. At the At the end the sleepers reach the effective range of the slewing crane (27) which the usable sleepers are available on a neighboring track standard sleeper transport vehicle (21) or other transport vehicle loaded for transport or placed on local surfaces. Thresholds that cannot be used are below the processing system or stored in a suitable rack and disposed of.

For reasons of railway operational safety, trains running on the tracks will Keep vehicles clear. This clear space (standard light room) results out of the limits for vehicles, overhangs and safety surcharges. Corresponding to the standard light room are according to the railway operating regulations (EBO) Vehicle limits set in normal operation by the rail vehicle and its superstructures must not be exceeded.

For working from rail vehicles, e.g. also for processing concrete sleepers exceptions are possible, which may also include railway safety measures (e.g. blocking the neighboring track, switching off the overhead line).

• 300 mm zu festen Teilen des Schienenfahrzeuges (einschließlich Aufbauten und Ladung)
• 1.500 mm von Personen

In addition, the following minimum safety clearances must be maintained on lines with overhead lines to these current-carrying lines:

• 300 mm to fixed parts of the rail vehicle (including bodies and cargo)
• 1,500 mm of people

All limitation and safety distances are for transport, work and Comply with disposal situations.

The standard distance between the top edge of the rail (SO) and the overhead line is in Average approx. 5,250 mm from the distance of the loading area of the conveyor, storage and loading system or the processing system for the SO of approx. 1,270 mm a permissible height of the modules and the superstructures, e.g. the cranes from 3,380 mm. Due to the design, the highest level is achieved in normal operation (Transport and work situation) the uncritical height of 2,880 mm.

The relevant mechanical components of the modules (pumps, etc.) electrically operated and from the self-sufficient, diesel-powered generator of the PLC unit (29) or in stationary operation powered by the local power network. The fuel supply in the generator is sufficient to cover several shift layers without additional fueling.

The fresh water reservoir of the PLC unit of approx. 8,000 l and the circuit management of the sub-process cleaning enables use without refueling several Working shifts, whereby in stationary operation also the connection to the local Fresh water supply is possible.

Dirty water is disposed of after several work shifts, the quality this water makes it possible to discharge it into public sewer networks. The filtering produces only a small amount, which may be considered Hazardous waste must be disposed of.

List of the reference symbols used

1 -

Combi tank fresh water area

2 -

feed pump

3 -

Water high-pressure pump

4 -

diesel engine

5 -

Entdübelungsmodul

6 -

cross-portal

7 -

High pressure lances

8th -

Collection and filtration containers

9 -

intermediate container

10 -

Feed and pre-pressure pump

11 -

cleaning module

12 -

high pressure pump

13 -

Cleaning Nozzle

14 -

Dirty water pump

15 -

-screener

16 -

PLC-internal sewage pump

17 -

Fine filter stage

18 -

Combi-tank process water area

19 -

Rail-driven high-pressure water system (PLC)

20 -

Side Channel Blowers

21 -

Swell transport vehicle

22 -

depository

23 -

Bridge crane / hoist

24 -

Conveying, storage and loading system

25 -

loader

26 -

Conveyors

27 -

jib crane

28 -

Control rooms Module

29 -

generator

30 -

High-pressure unit module

31 -

suction

32 -

receptacle

33 -

inspection module

34 -

dowel module

35 -

Swell transport vehicle

36 -

Vacuum-operated pump

37 -

Working up system

Claims (17)

Process for refurbishing parts of the substructure of rail-based means of transport, in particular sleepers which are preferably made of concrete, wherein sleepers removed from the rail-supported carriageway are freed from any fastening means still present, temporarily stored, refurbished and re-used,
characterized in that, in a largely automated process, the released sleepers are removed from a transport vehicle (21) or an intermediate storage location (22) via a lifting device (23) and fed to a conveyor, storage and loading system (24) from which they are conveyed into a rail-mobile or stationary treatment system (37) which is connected to a preferably rail-mobile high-pressure water system, in which removal of dowels (5) and cleaning of the sleepers (11) from impurities is carried out in several, preferably two modules , whereupon new dowels are set in a dowel module (34) and the repaired sleepers are in turn fed to a transport vehicle (35) or an intermediate store (22) via a further lifting device (27). A method according to claim 1, characterized in that a visual and / or a metrological control of the quality of the thresholds before the new dowelling in the dowel module (34) is preferably carried out between the debugging module (5) and the cleaning module (11) in an inspection module (33) , Method according to claims 1 and 2, characterized in that a bridge crane (23) mounted on a rail vehicle and movable thereon is used as the hoist. Method according to claims 1-3, characterized in that a water circulation method is used in the treatment system, in particular in the debulking and cleaning module (5; 11), the fresh water being taken from a combination tank (1) of the high-pressure water system, in the high-pressure unit module (30) is increased in pressure, then the thresholds are removed by means of high-pressure water lances (7) and the process water is passed through collecting and / or filtration and / or intermediate containers (8; 9) and then increased in pressure by high-pressure pump (12) to the cleaning module (11 ) fed, then collected in a collecting container (32), directed to a coarse and fine separation (15; 17) by means of a dirty water pump (14) and then fed to a process water area (18) of the combination tank (1). Method according to Claims 1 to 4, characterized in that the dirty water separated from the suction air in the coarse separator (15) after flowing through the ultra-fine filter (17) is fed to the process water area (18) of the combination tank (1) and is made available here for reuse , A method according to claims 1 to 5, characterized in that in the case of stationary modules, the supply of electrical energy is carried out via the local power network. Method according to Claims 1 to 6, characterized in that water mist which arises in the deblocking module (5) and in the cleaning module (11) is suctioned off by a suction system by generating a vacuum by means of a vacuum unit, preferably side channel compressors (20) and then reused. A method according to claim 7, characterized in that possible contaminants are separated from the water mist before its reuse. Method according to claims 1 to 8, characterized in that the quality of the exposed bores is examined via an inspection module (33). A method according to claims 1, 2 and 9, characterized in that thresholds which are not suitable for further use are identified and removed from the cycle at the end of the refurbishment process by means of a crane (27) and for subsequent disposal in a preferably below the rail vehicle or in the area of the stationary system in a suitable device, preferably a rack, or is immediately disposed of. Method according to claims 1 to 10, characterized in that the cleaned bores are provided with a filler before and / or at the same time as the new doweling. Method according to claims 1 to 11, characterized in that the dowels in the dowel module (34) are guided from a magazine to the bores, positioned there by means of a device and pressed into the bores by a pressure body, preferably a punch having a guide mandrel. Method according to claims 1 to 12, characterized in that the loading system (25) has pallets on which the sleepers are adjusted and fixed, these being returned to the beginning of the process after they have been run through the cycle method. Device for refurbishing parts of the substructure of rail-based means of transport, in particular sleepers, which are preferably made of concrete, characterized in that the rail-bound concrete sleeper refurbishment device has at least one hoist (23) with a stationary and / or a mobile concrete sleeper intermediate store (22; 35 ) and is equipped with a loading system, the concrete sleeper preparation device being composed of at least one module for removing the dowels (5) and for cleaning the sleepers of impurities (11) and that an inspection module at least between the two modules (5; 11) (33) and after the cleaning module (11) a dowel module (34) is arranged. Apparatus according to claim 13, characterized in that the refurbishment system preferably consists of two modules, which are composed of a dowelling (5) and a cleaning module (11), a combination tank (1) of a preferably rail-driven high-pressure water system (19) A feed pump (2) is connected to a high-pressure water pump (3) driven by an engine (4), preferably a diesel engine, which is coupled to a transverse portal (6) with high-pressure lances (7), under which a collecting and filtration container ( 8) and subsequently an intermediate container (9) is arranged, which in turn is connected via a further feed and pre-pressure pump (10) and, if necessary, a high pressure pump (12) to a cleaning nozzle block (13), below which a collecting container (32) is arranged, which is connected via a dirty water pump (14) to a coarse and a fine separator (15; 17) of a preferably rail-driven high-pressure water system t, which is coupled to the process water area (18) of the combination tank (1). Device according to claims 13 and 14, characterized in that the process water area (18) of the combination tank (1) is connected to the intermediate tank (9) which is coupled to the cleaning nozzle assembly (13) via the pumps (10; 12). Apparatus according to claim 13 to 15, characterized in that the high-pressure water system has a suction system for water mist, which is connected to the low-pressure coarse separator (15) via a suction line (31).

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