JP2006334644A - Method for forming rail bond - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for forming a rail bond, by which, even when damage such as breaking of wire is generated on the rail bond in a rail way, only a bond conductor is removed from the rail bond terminal, the terminal is left as welded and fixed, and only the bond conductor is replaced. <P>SOLUTION: The rail bond is formed as follows: a rail bond terminal, which is made of a conductive material, and whose end part is made to be inserted by a bond conductor, is welded and fixed to a rail by a copper thermit process at a position in a rail way, where a rail bond is required to be mounted; a bond conductor is inserted into the rail bond terminal welded and fixed to the rail; and the bond conductor is welded and fixed with a low temperature welding material. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for forming a rail bond for an electric circuit configuration provided at a rail-to-rail fastening portion in a railway, and a rail bond terminal.

Rail bonds in railroads are important components necessary for constructing a signal circuit or a power circuit for an electrically driven vehicle at a joint between rails. If it breaks or breaks, it will interfere with the signal and power circuit and will have a serious impact on train operation.
Usually, the rail bond is composed of a large number of electric wires made of a conductive material, and the rail bond terminal is fixed to the terminal, and the rail bond terminal of the terminal is welded and fixed to each rail of the rail and the fastening portion of the rail. Is configured.

  There are two methods for welding rail bond terminals to rails: the low-temperature welding method and the high-temperature welding method.The low-temperature welding method is a method of welding using welding materials such as solder and metal rods. During use, the rail bond terminal may be peeled off from the rail, the bond conductor may be disconnected, or the bond conductor may come off from the rail bond terminal. Both of these phenomena are mainly due to vibrations when passing through the train.

  In addition, rail bond is easy to fatigue the welded part of the cable conductor welded together with the terminal to the rail bond terminal part in the place where the vibration is strong such as the sharply curved rail or the rail on the bridge. JP-A-2005-14008 describes that cracks and breaks are likely to occur in the terminals. When a rail bond is damaged or disconnected, it impedes the operation of railway vehicles and requires immediate recovery.

JP 2005-14008 A

On the other hand, in the high temperature welding method, the welded portion of the rail bond terminal to the rail and the rail bond terminal are melted and the rail bond terminal is welded to the rail.
High temperature welding methods include copper thermit method, arc welding method, gas welding method, etc. Of these, copper thermit method is a method of mixing (oxidizing) copper oxide and aluminum powder in a crucible and reacting (combusting). Widely used as a means to fix the rail bond terminal that fixes the rail bond to the rail by melting the rail, the rail bond terminal and the bond conductor in the rail bond terminal by the high-temperature molten copper produced by reducing copper Has been.
Rail bond terminals fused and fixed to the rail by this copper thermit method will not fall off the rail, but rail bonds exposed to high temperatures when melted and fixed to the rail will vibrate when passing through the train while being used for a long time. For example, the bond conductor may be broken at the base of the rail bond terminal fixed by welding. This is presumably because the metal forming the rail bond is exposed to the high temperature during copper thermite welding, the metal structure changes, the crystal becomes larger and becomes brittle.
It is also known that when a rail bond is welded to a rail by a copper thermit method, the rail is affected by heat at a high temperature during welding.

  Rail bond welded to the rail is when the bond conductor is disconnected, when it is disconnected from the rail bond terminal, when a new rail bond is added to the existing rail bond, when the replacement time comes, or When replacing the rail itself, a new rail bond must be fixed by welding. In this case, in the case of a rail where the rail bond terminal has already been welded and fixed, there is a provision that the weld location of the newly provided rail bond terminal must not be duplicated with the previous weld location. It is necessary to provide it at a remote location. This is because the rail is thermally affected by the high temperature when the rail bond is welded by the copper thermit method, and when the high temperature is applied again at or near the same position, the strength of the rail is adversely affected.

The position where a new rail bond terminal is rail-bonded by the thermite method is subject to restrictions as described above, and the copper thermit is applied many times at places outside the limit. If welding is performed by the method, the damage to the rail itself is great, and the quality of the rail is degraded, which may cause an accident due to breakage of the rail.
In the present invention, even if breakage or the like occurs in the rail bond, only the bond lead wire constituting the rail bond is removed from the rail bond terminal by heating the rail bond terminal, and the rail bond terminal is left fixed to the rail. It is intended to provide a way to replace only the bond conductors when installing a new rail bond.

  The object of the present invention is to fix only the rail bond terminal to the rail by high-temperature welding, for example, a copper thermit method, and to bond the bond conductor to the terminal at a low temperature so that the bond conductor can be vibrated for other reasons. If a bond conductor needs to be replaced, remove the bond conductor that was welded to the rail bond terminal and form a rail bond that can be used over and over again so that a new bond conductor can be cold welded to the terminal. It is an object of the present invention to provide a method and a rail bond terminal used in the method.

In the present invention, a rail bond terminal made of a conductive material is welded and fixed to a rail by a high temperature welding method, for example, a copper thermit method, at a location where rail bond installation is required on a rail of a rail, and the bond conductor is connected to the rail bond terminal. In this method, a rail bond is formed by inserting low temperature and welding at low temperature.
Furthermore, when the rail bond needs to be broken or replaced, the present invention heats the rail bond terminal welded and fixed to the rail by the copper thermit method and removes only the bond conductor wire that has been welded at low temperature. In this method, a bond wire is inserted into a rail bond terminal and welded at a low temperature to form a rail bond.

  In the present invention, since the rail bond terminal welded and fixed to the rail by a copper thermit method and the bond conductor are welded with a low-temperature welding material, such as solder or metal iron, it is necessary to replace the rail bond due to disconnection or the like. In this case, the bond wire that has been welded to the rail bond terminal can be easily removed from the rail bond terminal by heating. It can be easily fixed by welding with a low temperature welding material. Also, it is not necessary to weld and fix the rail, rail bond terminal and bond conductor at the same time as when mounting the rail bond terminal by copper thermit method, so the bond conductor is not melted in the rail bond terminal and exposed to high temperature. Therefore, the copper metal constituting the bond conductor is not easily fragile, the chance of suffering from disconnection due to vibration when passing through a train or the like is reduced, and the construction quality is improved.

  In addition, according to the present invention, when a rail bond terminal that is initially welded and fixed to a rail by a copper thermit method is used to replace the rail, a new rail bond terminal is added to the rail in which the rail bond terminal is already installed. This eliminates the need for unnecessary heat effects on the rail and enables long-term use of the rail.

The rail bond terminal used for this invention is demonstrated referring an accompanying drawing. In addition, a method for forming a rail bond using the obtained rail bond terminal will be described.
A rod conductor (1) made of copper or copper alloy having a diameter of 16 mm and a length of 50 mm for forming the rail bond terminal shown in FIG. 1 is cut to a length of 27 mm from the right end to an inner diameter of 13 mm. (2), the subsequent portion (3) of 16 mm in length is cut to an outer diameter of 13 mm, and the intermediate portion (4) of 4 mm in length is cut to an outer diameter of 10 mm to obtain details and remain. The portion (5) having a length of 7 mm is not processed and remains the same outer diameter of 16 mm as that of the bond conductor insertion portion (2).
Next, a low-temperature welding material injection hole (6) having a width of 4 mm and a length of 12 mm is formed on the upper surface of the bond conductor insertion portion (2), and a low-temperature welding material injection confirmation hole having a diameter of 3 mm near the right end of the bond conductor insertion portion (2). (7) was provided to produce a rail bond terminal.
FIG. 3 shows an AA ′ cross section in FIG.

The rail bond terminal thus obtained is welded and fixed to a predetermined portion of the rail by a copper thermit method. An example of the welding fixing means will be described.
In FIG. 4, the conceptual diagram of the crucible for welding and fixing to a rail by a copper thermit method is shown. A mixture of copper oxide and powdered aluminum is charged into the reaction chamber (11) of the main body of the crucible (10), and an ignition agent is introduced into the reaction chamber from the upper part of the crucible. Copper passes through the runner (12) and reaches the rail bond terminal and the rail weld (chamber) (13). The welded portion (chamber) (13) opens at the center of the semi-circular rail bond terminal mounting portion (14) that accepts the rail bond terminal, and from the rail bond terminal mounting portion (14). It is preferable to increase the diameter.

  In order to weld and fix the rail bond terminal to the rail, the details (3) formed by cutting the rail bond terminal and the central part (4) are caused to flow down from the reaction chamber (11) through the runner (12). Allow molten copper to reach. The runner (12) opens to the welded part (chamber) (13) at an angle of approximately 90 degrees to the rail bond terminal mounting part (14). The rail bond terminal mounting portion (14) is installed so that the low-temperature welding material injection hole (6) and the welding material injection confirmation hole (7) of the rail bond terminal face upward, and the rail bond terminal mounting portion (14) As shown in FIG. 6, the rail and the crucible are temporarily fixed with a fixture (not shown) so that the rail bond terminal welding fixing surface of the rail comes into contact with the open surface.

  In the welded portion (chamber) (13), hot molten copper flowing down the runner (12) from the reaction chamber (11) of the crucible to the side surface of the rail bond terminal is welded to the rail, for example, the side surface of the abdomen of the rail ( 16) and the details (3) and (4) of the rail bond terminal, and the molten copper surrounds the rail bond terminal details (3) and the intermediate details (4) and its periphery, The terminal is welded and fixed together with the rail abdomen surface (16) by melting (17).

  The state is shown in FIGS. 5-1, 5-2. In FIG. 5A, reference numeral (17) indicates a welding portion between the rail and the rail bond terminal, and in this example, the side surface of the rail is shown. The rail bond terminal is welded and fixed so that the low temperature welding material injection hole (6) and the welding material injection confirmation hole (7) point upward, and the rail bond terminal in a state of being welded and fixed to the rail is the rail bond terminal. Copper is covered around the details (3) and the details (4) in the middle thereof (4), and is fixed to the rail by melting. In FIG. 5A, the hatched portion indicates a welded portion and a portion that is welded by a copper thermit method. FIG. 5-2 shows the rail bond terminal after welding, where a portion with a large outer diameter is a detail (3), particularly a portion with a large outer diameter is a detail (4) in the middle of the detail (3).

  As described above, the end of the bond conductor is inserted into the bond conductor insertion portion (reference numeral 2, indicated by an arrow in FIG. 1) of the rail bond terminal that is melt-fixed to the rail belly surface. The bond conducting wire (8) is composed of a number of annealed copper stranded wires, and the end portion is inserted until it abuts against the bond conducting wire insertion portion (2) cut out by the rail bond terminal. It is preferable to insert a metal sleeve (9) into the end of the rail bond terminal. Thereby, the bond conductor (8) can be smoothly inserted into the insertion portion of the rail bond terminal without disturbing a large number of metal wire bundles.

In the bond lead wire insertion portion (2) of the rail bond terminal, about 1/2 of the right length of the rod-shaped body constituting the rail bond terminal is on the right side, which exceeds approximately 1/2 of the entire length of the bond terminal. It is preferable to provide a welding material injection confirmation hole (7) having a diameter of about 3 mm in the vicinity of the right end of the (12 mm × 6 mm) long oval low-temperature welding material injection hole (6) and the bond conductor insertion portion (2).
In the present invention, molten solder is poured into the low-temperature welding material injection hole (6) of the rail bond terminal fixed upward on the rail, and the solder is bonded to the rail bond terminal by the welding material injection confirmation hole (7) provided near the right end. It can be confirmed by visual observation that the copper wire has been evenly penetrated.

In the present invention, when the rail bond is disconnected for some reason, the rail bond terminal is fixed to the rail, and the rail bond terminal is heated with a gas burner or the like to fix the bond lead wire. The low-temperature welding material is melted and the bond wire is drawn out, and a new bond wire is inserted there again by the above-mentioned means, and the welding material melt used for the low-temperature welding material, such as solder, is heated and melted from the low-temperature welding material injection hole (6). Then, the injection state is confirmed through the welding material injection confirmation hole (7), bond conducting is performed, and the rail bond is formed again.
In addition, the present invention can repeatedly use the rail bond terminal once welded and fixed to the rail by the high temperature welding method, and at the time of reuse, it is not necessary to use a high temperature as when welding the rail bond terminal to the rail. The heat effect on the rail is small, the bond replacement work time can be shortened, and the troubled operation time of the train can be shortened, for example, by speeding up the recovery of the accident.

  According to the present invention, since the rail bond terminal is welded and fixed to a predetermined portion of the rail by a copper thermit method, when the rail bond is disconnected due to a long-time train vibration or accident, the rail bond terminal is attached to the rail. By heating to a temperature lower than the temperature at which it was welded, the cut bond wire can be easily removed from the rail bond terminal, and a new bond wire can be inserted into this and welded again, and this is repeated. However, there is no thermal effect on the rail, and the bond replacement work time can be shortened, contributing to the safe operation of the train.

It is a top view of a rail bond terminal. It is a terminal diagram of a bond conducting wire. It is A-A 'sectional drawing of FIG. It is a perspective view of a crucible. 5-1 is a cross-sectional view of a rail with a rail bond terminal fixed by welding, and a side view of 5-2. It is a side view which shows the state set in order to weld and fix a rail bond terminal to a rail using a crucible.

Explanation of symbols

1: Rod-shaped body 2: Bond conductor insertion portion 3: Detail 4: Middle portion of detail 5: Left end portion 6: Low temperature welding material injection hole 7: Welding material injection confirmation hole 8: Bond conductor end portion 9: Sleeve 10: Crucible 11: Reaction chamber 12: Runway 13: Welded part (chamber)
14: Rail bond terminal mounting part 15: Rail 16: Rail abdomen 17: Melting part 18: Rail head

Claims (7)

  Rail bond terminals made of conductive material that can be inserted into the ends of rails where rail bond installation is required are welded and fixed to the rails by the copper thermit method, and the rail bonds are fixed by welding. A method of forming a rail bond in which a bond conductor is inserted into a terminal, and then the bond conductor is welded and fixed to a rail bond terminal with a low-temperature welding material.   When the rail bond needs to be disconnected or replaced, the rail bond terminal welded to the rail is heated by the copper thermit method to melt the low-temperature welding material and remove the bond conductor, and then add a new rail bond conductor to the rail bond. A method of forming a rail bond that is inserted into a terminal and fixed to a rail bond terminal again with a low-temperature welding material.   The method of forming a rail bond according to claim 1 or 2, wherein the rail bond terminal is welded and fixed by a high temperature welding method, and the rail bond terminal is used to repeat the new installation of the rail bond, the removal of the bond conductor, and the low temperature welding of the new bond conductor. .   The rail bond forming method according to claim 1, 2 or 3, wherein a sleeve is fitted into an end portion of a bond conductor made of a large number of stranded wires and inserted into a rail bond terminal.   A rail bond terminal made of a conductive material and having a length and a rail bond lead wire insertion portion provided with a detail and a rail bond conductor insertion portion, which can be welded and fixed to a predetermined position of the rail by a copper thermit method.   6. The rail bond terminal according to claim 5, further comprising a welding material injection hole for low-temperature welding the bond conductor inserted into the rail bond terminal fixed by welding to the rail bond terminal.   7. The rail bond terminal according to claim 5 or 6, further comprising a confirmation hole for confirming welding material injection.

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