EP2150652A1

EP2150652A1 - Method and device for foaming ballast beds

Info

Publication number: EP2150652A1
Application number: EP08748898A
Authority: EP
Inventors: Wolfgang Pawlik; Jürgen Wirth; Andreas Petersohn
Original assignee: Hennecke GmbH
Current assignee: Hennecke GmbH
Priority date: 2007-04-24
Filing date: 2008-04-12
Publication date: 2010-02-10
Anticipated expiration: 2028-04-12
Also published as: CA2684082A1; DE102007019669A1; CN101663437A; PL2150652T3; WO2008128665A1; KR101468245B1; MX2009011240A; JP4960499B2; KR20100015852A; BRPI0810398A2; BRPI0810398B1; RU2009143327A; CN101663437B; EP2150652B1; AU2008241025B2; JP2010525198A; ES2546207T3; RU2448211C2; AU2008241025A1; US20100140367A1

Abstract

The invention relates to a method and device for partially or completely foaming the hollow spaces in the ballast structure of a ballast bed, below which a subgrade (7) is located, having a reactive plastic, wherein the reactive components are mixed in a high-pressure mixer (1,26) and wherein the start time for the reactive mixture (4) is adjusted such that the foaming process substantially only begins when the reactive mixture has reached the subgrade (7).

Description

Method and device for filling ballast beds

The invention relates to a method for partially or completely foaming the cavities in the ballast structure of a ballast bed, under which a planum is arranged, with a reactive plastic, in which the reactive components are mixed in a high-pressure mixer and in which the starting time for the reactive mixture is adjusted, that the foaming process essentially begins only when the reactive mixture has reached the planum.

The traditional railway path consists essentially of the so-called planum applied ballast bed, in which the sleepers, which may consist of wood, concrete or steel, are embedded and on which the rails are attached.

However, a major problem with this well-proven technology is the wear of the ballast bed due to the driving operation. Wear is understood to be the gradual grinding of ballast stones by the enormous dynamic horizontal and vertical track forces. This grinding is essentially due to the fact that the ballast stones can rotate and move against each other, with the resulting extreme pressures particles break out of the ballast stones.

This wear of the ballast ultimately leads to track distortions and bumps in the rail, which must be eliminated by consuming and costly repairs. Repairs are made by replenishing ballast stones under the track grid and re-compacting the replenished ballast stones.

Various inventors have dealt with this entire complex of topics. Thus, DD 86201 has set itself the task of causing a substantial increase in the lateral displacement resistances and proposes to strengthen the threshold compartments by metering hardened plastic resins in the spraying or pouring process, whereby the plastic is atomised or cast as a film , That is, this patent describes measures to improve the ballast bed stability against horizontal track forces, namely by gluing the ballast stones in the upper part of the ballast stand together.

However, measures for improving the stability against vertical track forces are not described in this patent.

Measures for improving the ballast bed stability against horizontal and vertical track forces, however, are proposed in DE-OS 20 63 727. Also in this publication, the individual stones of the ballast tower to be glued by a binder, so as to prevent twisting and moving the ballast stones.

However, two methods are distinguished:

The stability against horizontal track forces is to be improved by gluing the ballast scaffold located laterally outside the two rails "at most" to about the threshold lower edge at the points of contact.

The stability against vertical track forces is to be improved by partially or completely filling the cavities of the ballast structure in the area under the sleeper bearing, so that the stones are adhesively bonded to the surface.

The gluing at the points of contact of the ballast stones in the upper area of the ballast tower should be done by "raining or trickling".

The surface bonding of the ballast stones to the substrate should be done by "injecting" the binder. Possibly, the inventors of the applications DE-OS 24 48 978, US-A-3 942 448 and EP-AI 619 305 from the reference in DE-OS 20 63 727, to inject the reactive plastic into the ballast tower, let. For both DE-OS 24 48 978 and US-A-3 942 448 describe special embodiments of injection lances.

However, EP 1 619 305 also refers to foam lances in order to inject the reactive plastic into the ballast structure.

Even DE-OS 23 05 536, which has actually made the lifting of tracks as a repair measure to the task, describes a special filling probe for injecting reactive plastic under the crossing point between rail and threshold.

However, these fill probes, foam lances or other devices for injecting liquid reactive plastic into the ballast structure of ballast beds described in the cited literature all have the same problem:

They tend to clog through the reactive plastic and must be rinsed after each injection with solvent, but at least with water and then blown dry with air, a measure that is ecologically no longer acceptable in this day and age. But also the time required to clean the injection devices and thereby unavoidable loss of raw material are also completely out of the question economically.

It was therefore the task for the per se known and quite useful foaming of the cavities in the ballast of a ballast bed with reactive plastic, as described in DE-OS 20 63 727 to prevent twisting and moving the ballast in the ballast and around thereby causing a substantial increase in the life of ballast beds to develop a suitable method and a suitable device in which, however, the cleanliness of the mixing and discharge system for the reactive mixture ecologically flawless and without loss of raw materials is feasible. The invention relates to a method for partially or completely foaming the cavities in the ballast structure of a ballast bed, under which a planum is arranged, with a reactive plastic, in which

a) the reactive components are required to metering at least one high-pressure mixing head and mixed there, and

b) the liquid reactive mixture discharged from the high-pressure mixing head is applied free-floating to the surface of the ballast structure,

characterized in that

c) the liquid reactive mixture is passed through the ballast bed through to the planum, and

d) then foaming the reactive mixture and allowed to rise by

e) the starting time for the reactive mixture is adjusted so that the foaming process essentially begins only when the reactive mixture has reached the planum.

Preferably, the reactive plastic is polyurethane.

A planum is the separating layer between the superstructure and the substructure of a track construction. As a rule, the superstructure consists of the track, the sleepers on which the track is fixed, and the ballast bed in which the sleepers are located.

With substructure while the entirety of the structures is referred to, which absorb the forces of the superstructure and dissipate into the ground.

In order to ensure the load capacity of the substructure permanently, it is often necessary to introduce additional protective layers between substructure and superstructure. This can serve as a base layer, which distributes the loads better on the ground, as an antifreeze layer, especially if the substrate consists of a frost-sensitive soil, as well as a filter and separating layer, which prevents mixing of the ballast with the substructure and as a cover with less Water permeability to protect water sensitive soils from surface water.

Further details on the plan can be found in the "Manual Track", 2nd edition 2004, ISBN 3-87814-804-6 from the Tetzlaff Verlag on pages 193-196.

Under a ballast bed is a heap of gravel to understand. Preferably, the ballast bed is a ballast bed for track systems, i. that in the upper part of the ballast bed sleepers are arranged, on which in turn rails are attached. In order to achieve a high storage density and tension of the ballast, the ballast is usually compacted in layers.

Here, gravel of different grain sizes can be used. It is common, for example, the use of gravel with a grain size of 22.4 to 63 mm. If necessary, this can also be mixed with gravel with a particle size of 16 to 22 mm.

More details about the gravel granules used in track beds can be found in the "Manual Track", 2nd edition 2004, ISBN 3-87814-804-6 from the Tetzlaff Verlag on pages 173-175.

Under a ballast, the gravel content of the ballast bed is to be understood in contrast to the cavities.

Figures 1 to 6 show an example of the solution for the described task. They illustrate a method for partially foaming the voids in the ballast of ballast beds with a reactive plastic, for example with polyurethane, wherein in the upper part of the ballast bed sleepers are arranged, on which in turn rails are attached. In this case, the reactive components are metered to at least one high-pressure mixing head and there mixed and anschießend the liquid reactive mixture applied by the high-pressure mixing head itself above the ballast bed on the ballast and allowed to flow through the ballast bed through to the subgrade under the ballast bed. Thereafter, the reactive mixture will foam and thereby rise. To effect this process, the so-called start time for the reactive mixture is adjusted so that the foaming process essentially begins only when the reactive mixture has reached the level.

With the method according to the invention, the criteria described in the problem for partially filling the voids in the ballast structure of ballast beds with a reactive plastic, e.g. Polyurethane, in order to prevent the twisting and shifting of the ballast stones in the ballast tower, completely fulfilled. It is essential that a high-pressure mixing head is used for mixing the reactive components.

In a high-pressure mixing head, the components are sprayed via nozzles, which convert the pressure energy into flow energy, into a small mixing chamber in which they mix with each other due to their high kinetic energy. The pressure of the components entering the nozzles is at an absolute pressure of more than 25 bar, preferably in a range between 30 and 300 bar. As a rule, the mixing chamber is cleaned mechanically after firing by means of a plunger. But there are also mixing heads, which are blown out with air. The main advantage of the high-pressure mixing head is the fact that these mixing heads can be cleaned much better and without the use of solvents after each shot.

As high-pressure mixing heads are one-, two- or three-stage mixing heads in question, all of which are self-cleaning. That is, in these types of mixing heads, the complete mixing and discharge system is mechanically cleaned by slide from reactive mixture, so that then no more complicated rinsing and cleaning operations are required. The decision as to whether a one-, two- or three-slide mixing head is used depends on the degree of difficulty of the mixing task for the reactive mixture.

In the case of an easy-to-mix raw material system, a squeegee mixing head is quite sufficient, for example the so-called "groove mixing head" well-known in the PUR (polyurethane) industry.

For more difficult mixing tasks, a two-slide mixing head, e.g. the MT mixing head of the company Hennecke, required.

For very difficult to mix raw material systems, it should be a three-slide mixing head, e.g. the MX mixing head of the company Hennecke. In this high-quality mixing system, there is a control valve for the mixing chamber area, a throttle slide for the throttle zone and a separate slide for the outlet area.

With such a mixing head not only excellent mixtures are possible, also the mixture discharge is completely laminar and splash-free through the separate outlet channel.

Therefore, a high-pressure mixing head is preferably used, which has a separate outlet channel, and through which the reactive mixture can be discharged laminar and free of spatter.

Also essential for this new process is the process optimized set start time for the reactive mixture. For only in this way is it possible to apply the reactive mixture above the ballast bed to the ballast structure, to allow it to flow through the ballast bed to the ground under the ballast bed and then lather it and thereby allow it to rise.

The start time is preferably set via the amount of activator in the recipe. A high proportion in the formulation causes a short start time, while a low proportion causes a long start time. The process is particularly flexible when the activator is dosed individually, as it can react directly and flexibly to the other conditions (ballast bed height, grain size, temperature). In this case, the usual activators in polyurethane chemistry, generally known amine-containing or organometallic catalysts can be used as an activator. Preferably, however, low-emission or emission-free catalysts should be used which are not elouted by precipitation water. Particular preference is given to using catalysts which react with the precipitation water to give ecologically harmless products.

These measures make it possible to flow the PUR reactive mixture through the ballast bed and to let it foam in that the load transfer cone below the thresholds is completely filled with foam, without appreciable amounts of foam flow into the adjacent areas, which in turn is a very important criterion for cost-effectiveness of the method.

With this new, surprisingly simple method, an ecologically completely harmless process is possible, but also offers great economic advantages, since no raw material losses occur here due to the mixing and discharge process.

The method is surprisingly simple in that, without lances immersed in the heap, it is possible to foam out defined areas in the heap which is limited only by free flow.

The starting time for the reactive mixture should be 3 to 30 seconds, preferably 4 to 20 seconds, particularly preferably 5 to 15 seconds. The start time to be set is dependent on the mixture viscosity of the raw material system, the grain size and packing density of the ballast bed, but above all on the ballast bed height H, which may be 20 to 40 cm, but in curves may also be 70 to 80 cm. In addition, the Schott temperature has an influence on the flow behavior and thus on the start time to be set. The appropriate start time can easily be determined empirically by considering the resulting foam cone as a function of the selected start time.

To account for this relationship, it is, as already mentioned advantageous to dose the start time determining catalyst or activator separately and the System. Various variants are possible here, the direct mixing into the mixing chamber or the mixing into the feed line of one of the main reactive components, polyol or isocyanate.

Another variant consists in providing one of the main components with a basic activation or basic catalysis and mixing in only further catalyst or activator if necessary.

Somewhat less flexible, but very cost-effective is the variant in which the activator in the desired amount in the Nachfüllmengenstrom one of the main components, preferably the polyol component, is metered and mixed.

In principle, however, it is also conceivable to use ready-to-use formulations in which the catalyst or activator is already admixed with one of the main components, preferably the polyol component, provided the formulations are storage-stable.

In a further process optimization, it is also possible to vary the size of the contact surface F between the planum and the reactive plastic and the rise height Zs of the foaming within the ballast bed the reactive plastic, namely essentially by the mass M applied reactive mixture, consistency of the chemical or physical parameters, such as Miscibility viscosity, blowing agent and thus foam density provided. The applied mass M in turn results from the product of mass flow m per unit of time and the metering time to-

For an optimal process flow, it is also very important that the mixture discharge at the outlet from the high pressure mixing head is as laminar as possible, so as to ensure a substantially aligned in the vertical direction, undisturbed flow through the reactive mixture through the ballast bed; This is because the mixing head type, as already mentioned, plays an important role, but also the speed with which the reactive mixture leaves the mixing head permissible speeds are very decisively dependent on the viscosity of the mixture, for example, with mixture viscosities above 1000 mPas Exit speeds up to 10 m / s possible. For mixed viscosities below 500 mPas, however, only approx. 1 to 3 m / s are permissible.

Preferably, the exit velocity from the outlet from the high pressure mixing head is adjusted so that a laminar flow of the reactive mixture is established at the outlet from the mixing head outlet.

An additional influencing factor for laminar mixture discharge is the distance d between the mixing head outlet and the ballast stand. In optimal conditions, e.g. Use of a three-slide mixing head and mixture outlet velocities of about 2 to 5 m / s and mixed viscosities in the order of 500 to 1000 mPas, distances up to 50 cm are quite possible.

Preferably, however, the distance should be only 0.5 to 10 cm.

In the further embodiment of this new method, the ballast stones are tempered in the ballast bed. This means that in winter at minus temperatures, the gravel stones are heated and cooled in the summer in extreme heat.

This is advantageous, because in this way it is possible to obtain almost constant process conditions, such as constant viscosity of the reactive mixture and constancy in the reaction kinetics. The optimum operating temperatures of the ballast stones are about 20 to 50 ° C, preferably at 25 to 40 ⁰ C, more preferably at about 30 to 35 ° C.

A particularly important application of this new method is the underfoaming of embedded in the upper part of the ballast bed sleepers, on which in turn rails are attached (see also Figures 3, 4, 5 and 6).

In this way, it is possible to fix the ballast stones in the so-called load transfer cone below the thresholds, over which the track forces occurring by the driving operation in the planum, in their position, so that they no longer twisting and shifting, whereby a significant increase in the life of ballast beds is achieved.

The underfoaming of the thresholds now happens that the reactive mixture is applied on both sides, immediately adjacent to the thresholds, and preferably at the same time on the ballast structure.

It is advantageous if at least two injection points in the vicinity of each support of the track are arranged on the threshold, since starting from these points, the load is discharged via the threshold and the ballast bed into the ground. In a preferred embodiment of the method according to the invention should each support of the railroad track on the threshold each 2 to 8 injection points not more than 40 cm away from this support of the railroad track on the threshold. Preferably, these injection points are located in each case half on both sides of the threshold.

In a process optimized with regard to the use of raw materials, it is even conceivable that the reaction mixture is injected exclusively in this area. It is better, however, if additional injection points are arranged over the entire threshold width, so as to minimize the total lateral resistance and the setting of the track due to the load. However, more than 24 injection points per threshold no longer make sense, since in this case the amount to be injected per injection point is so low that form no more suitable foam chimneys. Consequently, the reactive mixture should be injected per threshold at 4 to a maximum of 24 points and preferably at 8 to a maximum of 20 points.

If only one dosing unit and only one mixing head are available, it is possible to arrange a mixing head with a so-called "antler" (see Figures 3 and 4) .This is a simple stream splitting on several outlet pipes However, at least 0.5 m / s, so that the antlers do not clog too fast, this "antlers" is not self-cleaning and must therefore be replaced from time to time. The lifetime for such an antler depends on the reactivity of the reactive mixture. This method is thus only practicable for low-reactive raw material systems.

Such an "antler" may be a cheap plastic disposable item, and a metal "antler" may burn out after each use so that it can be used again.

The solution, which is certainly more expensive from the investment costs, consists in using two metering units and two mixing heads which discharge the reactive mixture at the same time on both sides of the threshold (see FIGS. 5 and 6). Otherwise, however, this method has the advantage of unrestricted applicability. This means that this variant can also be used for highly reactive raw material systems.

In the further embodiment of this method, the mixture entry takes place along the threshold, i. substantially parallel to the longitudinal axis of the sill (i.e., in the Y-axis direction in Fig. 8), and preferably substantially in a passage which is interrupted for a short time only during traversal of the rails. That is, interrupted in these phases, only the Gemischaustrag, but not the further transport of the mixing heads.

If only one dosing unit and only one mixing head are available, it is also possible to control the mixture entry along the threshold, i. substantially parallel to the longitudinal axis of the threshold (i.e., in the Y-axis direction in Fig. 8). The reaction mixture is preferably injected at regular intervals at at least 6 points per threshold side. In this case, the reaction mixture is preferably initially introduced at each of the at least 6 positions along the Y axis in FIG. 8 at an Y position on both sides of the threshold, before the next position (on the Y axis) is approached along the threshold ,

This procedure is possible in particular if the time sequence for both of the longitudinal axis of the threshold each mirror-image mixture entries and indeed in each case to the planum within the starting time of the reactive mixture. Although this method variant is less expensive than the investment outlay for two mixing heads in terms of the investment costs in terms of the investment costs, in terms of production costs, ie substantially less favorable in terms of production times.

In the further embodiment of the method, the mixture entry along the threshold (kg reactive mixture / cm distance) is a function of the distance (ie of Y in Fig. 8), so that the rise height Zs of rising in the ballast scum a function of the distance (ie from Y in FIG. 8) (see also FIGS. 7 and 8).

In order to achieve this, there are basically two options. On the one hand, it is conceivable, in particular in the variant with simultaneous mixture entry on both sides of the threshold, to change the mixture discharge per unit of time at a constant mixing head feed. However, it is simpler to change the mixing head feed rate with a constant mixture discharge.

However, in the variant with alternating mixture entry along the threshold, the adaptation of the metering time from step to step is the more sensible method.

This method variant (rise height Zs - f (Y), ie function of the distance parallel to the longitudinal axis of the threshold) makes it possible, as shown in FIGS. 7 and 8, for Zs to increase steadily from one side to the other of the ballast bed, the gradient being approximately 2 ° to 10 °, preferably 3 ° to 8 °, particularly preferably 4 ° to 6 °. This causes ZR to rise accordingly from one side to the other of the ballast bed (see FIGS. 7 and 8 again). Namely, Z _R = f (Y) is the intersection line formed between two foam peaks at adjacent thresholds. Due to the inclination of these forming between the foam mountains gutters, it is thus possible to drain the located above the foam mountains free gravel zones, so that no harmful waterlogging throughout the ballast bed can arise.

A variant of the ballast bed drainage consists in the center line of the ballast bed seen in the direction of travel, quasi form a watershed, ie that the maximum rise height Zs _max is in the middle of the sleeper and the troughs extend from the ballast bed center to the ballast bed sides.

This allows a double strong slope. Such increased slope not only provides improved drainage, it also provides a greater tolerance for local inclination angle variations, which may well result from riser tolerances of the plastic gates.

In an advantageous embodiment of the method, the ballast bed ends at the time of foam entry at the lower end of the thresholds and can optionally be further filled then. In this case, the reaction mixture can be entered immediately next to the threshold. This makes it even more purposeful to foam only the load transfer cone, which can reduce the consumption of raw materials somewhat, which of course has a positive effect on the cost-effectiveness of the process.

The invention also relates to a device for foaming the cavities in the ballast structure of a ballast bed, under which a planum is arranged, comprising a reactive plastic

a) a rail vehicle, and

b) at least one arranged on the rail vehicle metering unit for metering a polyol-containing reactive component, which is hydraulically connected via lines with the associated containers for the polyol component, and

c) at least one arranged on the rail vehicle metering unit for metering an isocyanate component, which is connected via lines to the associated containers for the isocyanate component, and

d) at least one high-pressure mixing head, which is hydraulically connected via lines with the metering units for the polyol-containing reactive component and for the isocyanate component, and e) at least one metering unit for an activator or catalyst which is hydraulically connected via lines to the metering unit or the associated container for one of the reactive components or directly to the high-pressure mixing head.

As a mixing head, a self-cleaning high-pressure mixing head, whether a one-, two- or three-slider mixing head, has the preference in any case. Although there are also air cleaned high-pressure mixing heads, the use of which would significantly reduce the benefits of the described method, especially in ecological terms.

To supply the high-pressure mixing head with the reactive components, the metering units for the two reaction components polyol and isocyanate must be suitable for applying absolute pressures of at least 25 bar, preferably from 30 to 300 bar.

The dosing unit for the activator is important in order to be able to react flexibly to the other conditions (ballast bed height, grain size, temperature). The most flexible solution is to dose the activator individually into the mixing head. An alternative is the seeding of the polyol stream with the activator, which is then injected via the polyol nozzle into the mixing chamber. In this case, however, the activator may only be injected during the firing time, otherwise it accumulates undefined in the polyol container. Also conceivable is the seeding of the isocyanate stream with the activator.

A more favorable and generally just as practicable solution is the dosing of the activator in a metered Nachfüllstrom one of the reaction components. To this

There is a batch approach with the appropriate activation available. Of course, this variant is a little less flexible, as the activation can not be changed from shot to shot. Since the other conditions such as temperature,

However, ballast bed height or grain size also usually does not change abruptly, this may still be a viable solution.

The metering unit for the activator is usually a suitable metering pump. However, other types of dosage are also conceivable. For example, could the activator can also be metered into one of the reaction components by means of pre-pressure and a flexibly controllable, fast-switching valve.

In order to be able to use the device in every season, it is necessary that aggregates for tempering the ballast bed are also arranged on the rail vehicle. In order to have the optimal temperatures of about 15 ⁰ C to 35 ° C for the foaming process, it is necessary in the cold season to heat the ballast bed accordingly and to cool on hot summer days.

It is just as important for the foaming process to dry the ballast bed, because water reacts with isocyanate, so that in a wet ballast bed, the foaming process would run completely uncontrolled.

In a preferred embodiment of the method, therefore, the ballast bed is first produced from washed, dried and compacted ballast. Either the dry ballast bed is then immediately foamed directly after the characterizing features of claim 1 according to the invention or it is temporarily covered to protect against rainfall in a suitable manner to keep it dry until the time of foaming. For this purpose it is e.g. possible to lay a tarp over the dry ballast bed. But even the use of simple, mobile wagons, which consist in the simplest case only of a scaffold with cover and wheels, is conceivable. The advantage of this variant is that the

Of course, gravel can be dried much easier if it is not already in the gravel

Track bed is located. Otherwise, it is only possible with very great energetic effort to dry the ballast to Planum. It would be ideal if the foaming machine is located directly behind the machine, which produces the ballast bed, so that the dry

Ballast bed is always filled directly.

It is also advantageous if handling devices for guiding the at least one mixing head are available on the rail vehicle since self-cleaning mixing heads can be relatively heavy. Thus, the weight of such a mixing head 10 kg, but also be 50 kg. In the further embodiment of this device, the handling devices are also associated with a sensor to position the mixing head. In this way it is possible to run the foaming process completely automatically.

Preferably, the outlet from the high pressure mixing head is oriented substantially vertically (i.e., at a maximum angle of inclination to the vertical of 10 °) so that the reactive mixture can be discharged as laminarly as possible (i.e., avoiding splashing) in a free-flowing manner in the vertical direction. In other words, the spout from the high pressure mixing head is oriented substantially perpendicular to the direction of travel of the rail vehicle (i.e., at a maximum angle of inclination to the direction of travel of 10 ° to the direction of travel).

In a further embodiment of the device, the rail vehicle has wheels, wherein the outlet from the high-pressure mixing head in the discharge from the high-pressure mixing head is at most 30 cm in front of the rearmost in the discharge direction of the wheels and particularly preferably in the discharge rearmost extent of the wheels even towers. Most preferably, the outlet from the high-pressure mixing head projects beyond the rearmost extent of the wheels in the discharge direction by up to 15 cm, particularly preferably by up to 10 cm. It is thereby achieved that the preferably laminar mixture discharge from the high-pressure mixing head impinges precisely on the ballast stand in order to ensure a substantially vertically aligned, undisturbed flow through the reactive mixture through the ballast bed. Because with a turbulent, spurting mixture discharge, the reactive mixture would spread far beyond the surface of the ballast structure and the reactive mixture in the ballast stand would almost "run".

The invention will be explained in more detail with reference to the following diagrams.

Show it:

FIG. 1 and FIG. 2 schematically show the basic sequence of the method according to the invention, Figure 3 and Figure 4 schematically shows the foaming of a threshold with a

High-pressure mixing head with antlers,

FIG. 5 and FIG. 6 schematically show the underfoaming of a threshold with a tandem mixing head system,

FIG. 7 shows schematically a track section with a plurality of underfoamed

Thresholds in section A 4 -A (corresponding to FIG. 8),

8 shows schematically a ballast bed in section B T B (corresponding to FIG. 7), and FIG

9 shows schematically a device according to the invention for partial

Foaming the voids in the ballast of a ballast bed with reactive plastic, e.g. with polyurethane.

In FIG. 1, polyurethane reactive components of storage containers are fed by means of metering units (not shown in the diagram) by means of connecting lines 2, 3 to a self-cleaning high-pressure mixing head 1 and mixed there. Subsequently, the liquid reactive mixture 4 above the ballast bed 5 is applied to the ballast tower 6 (i.e., the ballast portion of the ballast bed) and allowed to flow through the ballast tower to the ground 7.

The mixture discharge is completely laminar and splash-free at a mixture viscosity of about 600 mPa sec and a discharge rate of about 3 m / s at a distance d of about 50 mm between ballast stand and mixing head outlet.

The ballast bed has a height H of about 30 cm in the example shown in FIG. The dosing time is about 2 sec. After about 4 seconds, the liquid reactive mixture has reached the planum and distributed on the surface 7 over an area F of about 350 cm ² . After a further approx. 2 seconds, the chemical reaction of the polyurethane reactive mixture begins (see also FIG. 4). That is, the starting time for the polyurethane reactive mixture is also about 6 sec. The chemical reaction produces propellant gas, through which the reactive mixture foams and rises through the ballast structure 6 in the ballast bed 5.

The rise height Zs of the foamed reactive plastic is about 25 cm. Approximately 30 seconds after the beginning of the reaction, the foaming process is completed and the reactive plastic hardens, forming a vent 9 of reactive plastic in the ballast of the ballast bed in the area of which ballast stones 8 are fixed in position and so can neither twist nor move.

FIG. 3 schematically shows a special application of the method according to the invention, namely the underfoaming of a threshold. In this case, polyurethane reactive components of storage containers via a metering unit (not shown in the diagram) are conveyed by means of connecting lines 2, 3 to a self-cleaning high-pressure mixing head 1 and mixed there. The high-pressure mixing head 1 is followed by a so-called antler 10, by means of which the liquid reactive mixture 4 is applied symmetrically to the vertical transverse axis 11 of the threshold 12 arranged in the upper region of the ballast bed 5 on the ballast structure 6. The mixture entry takes place on both sides immediately adjacent to the threshold 12, in this case at the same time. The lateral distance between the threshold and the mixture inflow into the ballast tower is approximately 20 mm on each side of the threshold in this example.

The liquid reactive mixture 4 is also applied in this application above the ballast bed 5 on the ballast tower 6 and allowed to flow through the ballast tower through to the planum 7.

The mixture entry is at a mixture viscosity of about 600 mPas and a discharge rate of about 3 m / s, at a distance d of about 50 mm between ballast 6 and the mixture outlet from the antlers 10 completely laminar and free of spatter.

The ballast bed also has a height H of about 30 cm in this example. The dosing time is about 2 sec. After about 4 seconds, the liquid reactive mixture 4 has reached the planum 7 and distributed on the planum on the surface F shown in Figure 4 of about 350 cm ² . After a further approx. 2 seconds, the chemical reaction of the polyurethane reactive mixture begins (see also FIG. 4). That is, the starting time for the polyurethane reactive mixture is also about 6 sec.

The chemical reaction produces propellant gas, through which the reactive mixture foams and rises through the ballast structure 6 in the ballast bed 5. The rise height Zs of the foamed reactive plastic is about 25 cm.

After a total of about 30 seconds after the start of the reaction, the foaming process is completed and the reactive plastic cures, whereby a vent 9 of reactive plastic (see also FIG. 4) is formed in the ballast structure of the ballast bed, which extends into the lower region of the threshold 12 and the ballast stones 8 fixed in place in the so-called load transfer cone below the threshold 12 and thus secures against twisting and shifting.

In this way, the edge pressures between the ballast stones, as a result of the driving introduced into the ballast bed forces, reduced and thereby in turn prevents crushing of ballast stones, so that the life of ballast bed is substantially increased.

FIGS. 5 and 6 show a variant of underfoaming of sleepers 12 arranged in the upper region of ballast beds 5. Polyurethane reactive components of storage containers, but in this case via two metering units (not shown in the diagram), also become two high-pressure mixing heads 1a, 1b promoted and mixed there.

The Gemischaustrag from the two high-pressure mixing heads Ia, Ib again takes place symmetrically to the vertical transverse axis 11 of the threshold 12, preferably at the same time. The lateral distance between the threshold and the respective mixture inflow into the ballast tower is approx. 20 mm. Larger lateral distances of up to approx. 50 mm enable a considerably greater tolerance for the mixing head guide system (see also FIG. 9) and are quite permissible. The procedure is the same as already described in FIGS. 1 and 2 as well as 3 and 4. The ballast bed height H is again 30 cm.

The dosing time, however, is slightly longer in this example. It is about 2.5 sec. This changes the flow time for the liquid reactive mixture through the ballast tower to about 5 sec, but is still within the starting time of 6 sec. The wetted with liquid reactive plastic surface F on the planum is accordingly also larger, as shown in Figure 6. It is now about 440 cm ² . Also, the height of rise Zs gets bigger. It now roughly corresponds to the ballast bed height of 30 cm.

FIG. 7 schematically shows a track section with a plurality of underfoamed sleepers 12a, 12b. This is particularly clear how the ballast stones are fixed within the load transfer areas below the thresholds 12a, 12b by the polyurethane plastic in position. However, FIG. 7 also shows that channels 13a, 13b form below the thresholds between the individual plastic channels 9a, 9b.

FIG. 8, which corresponds to FIG. 7, shows a solution in which the outflow of water through the channels 13a, 13b is favored.

(Figure 7 is the section A - * - A in Figure 8 and Figure 8 is the section B - = - B in Figure 7)

The channel 13b between the plastic channels 9a, 9b below the sleepers 12a, 12b are inclined transversely to the ballast bed 5 in this example. In this way, no possibly damaging backwash water can form in the free gravel areas above the plastic channels 9a, 9b.

The inclination angle is approximately 5 ° in the example shown. The maximum possible inclination angle is in this example essentially determined by the threshold length and the threshold _thickness , because the maximum possible _{vertical rise difference} (Zs _max - Zs _mιη ) then corresponds approximately to the threshold _thickness . In any case, Zs _mm must still be so high that at this point a properly foamed load transfer cone is below the threshold and Zsmax should in turn not significantly exceed the ballast bed height. Since (Zsmax - Zsmm) is approximately proportional to (Z _Rmax - Z _Rmin ), a corresponding inclination angle also results for the drainage channels.

Figure 9 shows schematically a device 20 according to the invention for partially filling the cavities in the ballast structure 6 of a ballast bed 5 with reactive plastic, e.g. with polyurethane.

On a rail vehicle 21 with drive 22 container 23 and a double metering 24 are arranged for the reactive components. Furthermore, there is a three-coordinate Mischkopfführungssystem 25 for a tandem mixing head system with two mixing heads 26 on the rail vehicle 21. The connecting lines between containers, Doppeldosieraggregat and the mixing heads are not shown in this diagram.

The Y coordinate guidance is necessary to guide the mixing heads 26 along the thresholds 27.

The Z coordinate guidance is required in order to lift the mixing heads 26, on the one hand, over the rails 28, but, above all, to position them in the required distance to the ballast structure 6.

Since the rail track not only runs straight, but also includes curves, an X coordinate guidance is necessary.

In order to enable automatic operation, the mixing head guidance system is also assigned a sensor system 29, which transmits the threshold and rail positions to a superordinate control device 30 and controls the X, Y, Z movements of the mixing head guidance system 25.

To effect this, lead impulses (represented by broken lines) from the sensor 29 to the controller 30 and from there to the mixing head guide system 25th When a threshold area has been completely filled, the control unit 30 gives an impulse to the drive 22 for the rail vehicle 21, so that the next threshold position is approached.

On the rail vehicle 21 and a temperature control unit 31 is arranged. About a - not shown in the diagram - temperature sensor, the temperature of the ballast stones is transmitted to the control unit 30, which in turn switches the temperature control unit 31 when needed. The optimum temperature for the foaming process is around 30 ° C. In other words, in winter, the gravel must be heated and cooled in the summer heat.

The conditions (pressure, temperature, level) for the container 23 and the Doppeldosieraggregat 25 are monitored by means not shown in the diagram indicators and transmitted to the control unit 30, which either outputs a signal in a tolerance violation or initiates a corresponding measure (in the scheme, however not shown).

Figure 9 also shows the preferred embodiment in which the discharge from the high pressure mixing head 26 in the discharge direction from the high pressure mixing head (i.e., substantially in the vertical direction) overhangs the rearmost extent of the wheels (i.e., the contact point of wheels and rail 28). It is thereby achieved that the preferably laminar mixture discharge from the high-pressure mixing head impinges precisely on the ballast stand in order to ensure a substantially vertically aligned, undisturbed flow through the reactive mixture through the ballast bed.

Claims

claims:

Anspruch [en] A process for partially or completely foaming the cavities in the ballast structure of a ballast bed, under which a subgrade (7) is arranged, with a reactive plastic in which

a) the reactive components to at least one high-pressure mixing head (1, 26) are metered and mixed there and

b) the liquid reactive mixture (4) discharged from the high-pressure mixing head is applied free-floating to the surface of the ballast structure (6),

characterized in that

c) the liquid reactive mixture is passed through the ballast bed (5) through to the planum (7), and

d) then foaming the reactive mixture and allowed to rise by

e) the starting time for the reactive mixture (4) is adjusted so that the

Foaming process essentially only begins when the reactive mixture has reached the planum (7).

2. The method according to claim 1, characterized in that the starting time for the reactive mixture is 3 to 30 sec.

3. The method according to claim 1 or 2, characterized in that the starting time is determined by a catalyst or activator, which is metered separately into the high-pressure mixing head and mixed.

4. The method according to claim 1 or 2, characterized in that the starting time is determined by a catalyst or activator, which is inoculated separately into the metering of one of the main components.

5. The method according to claim 1 or 2, characterized in that the starting time is determined by a catalyst or activator, the separately in the

Nachfüllmengenstrom one of the reactive components is metered and mixed, this reactive mixture is then fed to a working container.

6. The method according to any one of claims 1 to 5, characterized in that the size of the contact surface F between the Planum (7) and the reactive plastic and the height of rise Zs within the ballast bed (5) foaming reactive plastic by adjusting the applied mass of reactive mixture (4) is determined.

7. The method according to any one of claims 1 to 6, characterized in that the reactive mixture at a rate of 0.5 to 10 m / s, preferably from 1 to 8 m / s, more preferably from 2 to 5 m / s from the at least one high-pressure mixing head emerges.

8. The method according to any one of claims 1 to 7, characterized in that the distance d between the at least one high-pressure mixing head and the ballast tower maximum of 50 cm, preferably at most 30 cm, more preferably at most 10 cm.

9. The method according to any one of claims 1 to 8, characterized in that the ballast stones are tempered in the ballast bed.

10. The method according to any one of claims 1 to 9, characterized in that the reactive mixture is applied on both sides, immediately adjacent to the thresholds on the ballast and that at the same time.

11. The method according to claim 10, characterized in that the mixture entry takes place along the longitudinal direction of the threshold and substantially in one passage, wherein during the crossing of the rails of the mixture entry is interrupted in each case for a short time.

12. The method according to any one of claims 1 to 9, characterized in that in the upper part of the ballast bed sleepers (12, 12a, 12b, 27) are arranged, and the mixture entry along the longitudinal direction of the thresholds in double steps and in each case from one to the other Side of the threshold is done alternately.

13. The method according to any one of claims 11 or 12, characterized in that the mixture entry along the thresholds (kg / cm) is a function of the distance along the longitudinal direction of the threshold, so that the rise height Zs of the rising foam is a function of the distance along the longitudinal direction of the threshold.

14. The method according to claim 13, characterized in that Zs increases steadily from one to the other side of the ballast bed, wherein the slope is 2 ° to 10 °.

15. An apparatus (20) for foaming the cavities in the ballast structure (6) of a ballast bed (5), under which a subgrade (7) is arranged, with a

Reactive plastic, comprising

a) a rail vehicle (21), and

b) at least one metering unit (24) arranged on the rail vehicle for metering a polyol-containing reactive component which is hydraulically connected via lines to the associated containers (23) for the polyol component, and c) at least one arranged on the rail vehicle metering unit for metering an isocyanate component, which is connected via lines to the associated containers for the isocyanate component, and

d) at least one high-pressure mixing head (26) which is hydraulically connected via lines with the metering units for the polyol-containing reactive component and for the isocyanate component, and

e) at least one metering unit for an activator or catalyst which is hydraulically connected via lines to the metering unit or the associated container for one of the reactive components or directly to the high-pressure mixing head.

16. The apparatus according to claim 15, characterized in that on the rail vehicle, a working container containing a mixture of polyol and the activator or catalyst is present, and that this working container via lines with a further metering unit for a polyol component and with reservoirs for the polyol component and hydraulically connected to the metering excavator and a reservoir for the activator, wherein between the metering units and the working container a mixing device for the mixing of the activator or catalyst is present in the polyol stream.

17. The apparatus according to claim 16, characterized in that on the rail vehicle and units (31) are arranged for tempering the ballast bed.

18. Device according to one of claims 15 to 17, characterized in that aggregates for drying the ballast bed are arranged on the rail vehicle.

19. Device according to one of claims 15 to 18, characterized in that on the rail vehicle and handling devices (25) are arranged for guiding the at least one high-pressure mixing head.

20. The apparatus according to claim 19, characterized in that the handling devices (25) is associated with a sensor (29) for detecting the positions of arranged on the ballast sleepers (27) or rails (28).

21. The apparatus according to claim 15, characterized in that the rail vehicle has wheels, wherein the outlet from the high-pressure mixing head in

Discharge direction from the high-pressure mixing head maximum 30 cm before the in

Austragsrichtung rearmost extension of the wheels is located and preferred in

Discharge direction rearmost extent of the wheels even towered over.

22. The apparatus according to claim 15, characterized in that the outlet from the high-pressure mixing head is aligned substantially perpendicular to the direction of travel of the rail vehicle.