RU2630362C1 - Manufacturing method and arrangement of non-ballast railway track module - Google Patents

Abstract

FIELD: transportation.

SUBSTANCE: non-ballast railway track module contains reinforced concrete rail beams, between which the cross-bars are installed. On the top of the beams there are support plates on which the rails are mounted. The support plates are fitted with retainers. Reinforced concrete underrail beams are made in geotextile shell, on which the clamping brackets are mounted. There are support plates installed above the clamping brackets and attached to the side walls of the brakets from the inner side. The method for manufacturing non-ballast railway track module includes laying the reinforcing frame, filling the mould with concrete mix, holding the module in the mould untill the concrete mixture cures, then removing the module from the mould and turning it over. Rails and locks are fixed above the beams, geotextile covers are placed on the reinforced frames of the reinforced concrete underrail beams, the module workpiece in overturned and placed in the steel mould.

EFFECT: increase the track geometry stability.

9 cl, 8 dwg

Description

The invention relates to railway transport, and in particular to the upper structure of a ballast-less rail [E01B 1/00].

In traditional track designs, ballast is designed to create an easily replaceable and relatively durable base for laying sleepers. This foundation is the top layer of the embankment and performs a variety of functions during the operation of the track, namely: it ensures the stability of sleepers to the action of vertical and horizontal loads, reduces the vertical pressure of sleepers on the underlying layer, creates an elastic cushion under the sleepers, absorbs dynamic shock loads, creates paths for drainage and removal of foreign substances, and also provides conditions for knocking down sleepers. During the operation of the railway track, foreign substances pollute the ballast, while most of their functions do not perform ballast. In addition, gravel pits are required for ballast mining, additional transport is needed for ballast delivery, special machines and equipment for filling the ballast are required, while the operation of the tracks becomes impossible during ballast replacement.

In those cases when the ballast is not convenient for the device of the rail track, the optimal ways of arranging the railway tracks are those that do not provide for its use. In the 50s of the 20th century, ballastless track structures were recognized for their advantages in comparison with ballast systems in terms of repair costs, however, the capital costs of their construction were high, therefore these systems were used only on specialized sections of the track: tunnels and high-speed roads.

Various ballastless track device systems are used and exist in the world, mainly block systems. It is understood here that the system has discrete rail supports, for example, reinforced concrete blocks, poured manually onto finished substrates.

The ballastless rail track is known from the prior art [World Railways magazine, 2000, No. 8], which contains a reinforced concrete slab on which reinforced sleepers are installed, while the slab and sleepers are reinforced with bar reinforcement, and reinforced concrete sleepers are connected with stove bottom part. For the construction of this construction of the track, a large amount of concrete and metal reinforcement is required, which makes the track in question quite expensive. Reinforced concrete products (slab and railroad ties) used in a known way experience a significant number of freezing / thawing cycles during their service life, which can cause damage to the concrete structure as a result of expansion of water during freezing in its capillary pores. The resulting cracks in the slab and sleepers spread in all directions and have a large length. Carbon monoxide and chloride penetrating through the cracks can lead to corrosion of the reinforcement, and then to the sudden destruction of both slabs and sleepers.

In addition, the rigid structure of the track can be damaged under the influence of cyclic and dynamic loads arising from the passage of rolling stock. The resulting damage will lead to a decrease in bearing capacity and to uneven deformation of the track as a whole, which is the reason for the emergence of extremely undesirable additional stresses of rail lashes.

The presence of a protective layer of concrete, which serves to reduce the electrical conductivity of reinforced concrete products and to protect reinforcement from external influences, high temperature, aggressive environment, etc., increases the consumption of concrete and the cost of the product.

The ballastless track RHEDA2000 [http://zab.megalink.ru/conference/stat_ya_savin_v_zabiizht_2013.pdf], which consists of modified two-unit sleepers with protruding reinforcement, which are mounted in a monolithic reinforced concrete bearing layer so that the reinforcement when laying, it is connected with the reinforcement of the bearing concrete layer. This analogue is inherent in all the main disadvantages of the first analogue, namely, the high material consumption of concrete and reinforcement, as well as low stability of geometric parameters.

The closest in technical essence is the ballastless track [http: scbist.com/videothumbnails/YouTube/oEVOnccdHcl.tif], which contains transverse reinforced concrete beams, which are interconnected by a reinforcement cross member, on which the supporting plates are mounted on the rail beams clamping mechanisms, between which the rails are installed. Clamps are installed in the clamping mechanisms, which are made with the possibility of pressing the sole of the rail to the support plates, while the method of manufacturing the modules is characterized in that the reinforcing cage of the reinforced concrete rail beams and cross members are laid upside down in the mold, after which the mold is filled with concrete, the module is held in form until the concrete mixture hardens, after which they take the module out of the mold and turn it over, on top of the beams install support plates with fixing mechanisms on which I lay rails, whereupon the latches mounted and is pressed against the rail clamps the sole to the support plates. At the installation site, the modules are poured with concrete in order to form a monolithic rail-reinforced concrete platform, which is reinforced with reinforcing cross members.

The disadvantage of the prototype is the large consumption of concrete and iron reinforcement for the manufacture of modules ballastless railway track, as well as low stability of geometric parameters and strength indicators due to the destruction of concrete under the influence of harmful environmental factors.

The technical result of the invention is the creation of a structurally and technologically simple module ballastless track with reduced material consumption, having high accuracy and stability of geometric parameters, with high strength and elasticity, ensuring the stability of the track geometry.

The specified technical result is achieved due to the fact that the method of manufacturing the ballastless rail module, characterized in that the reinforcing frame of the rail reinforced concrete beams is turned upside down in the mold, the mold is filled with concrete mixture, the module is held in shape until the concrete mixture hardens, and then the module is pulled out from the mold and turn it over, rails and fixators are installed on top of the beams, with which the rail soles are pressed, it differs in that iron is reinforced on reinforcing cages concrete beams are put on geotextile sheaths, on which clamping brackets with support plates and loops for fastening the rails, as well as clamping brackets between which steel cross members are installed, are put on with a predetermined step and alternation, after which the module blank is laid upside down in a steel mold, closed the lid and pump the concrete mixture into the geotextile casings from the end face of the mold into the geotextile casings, hold the module in the mold until the concrete mix hardens, then remove the module from the mold and turn it over, Between the loops of the rail girders, elastic gaskets are placed on which the rails are installed, after which the clips are inserted into the loops and installed so that the clamps press the rail soles against the elastic gasket.

In particular, a self-compacting concrete mixture with a fine filler is injected into the geotextile sheath.

The indicated technical result is achieved due to the fact that the ballastless track module containing reinforced concrete rail beams, between which the cross members are installed, support plates on which the rails are installed on top of the beams, while the support plates are mounted on the support plates, which are capable of pressing the rail soles, characterized in that reinforced concrete rail girders are made from 3 to 6 meters long in a geotextile casing, on which U-shaped joints are installed with a given step Many brackets are made in the shape and size of the base and side walls of the rail beams, on top of the clamps in the plane formed by the upper parts of the rail beams, support plates are installed, which are attached to the side walls of the brackets by connecting elements on the inside, with cross members installed between some brackets , loops are installed on top of the support plates, between which elastic gaskets are laid along the entire length of the rail beams, rails are installed on top of which, while loops are installed in the loops clips.

In particular, the length of the rail corresponds to the length of reinforced concrete rail beams.

In particular, the cross-members are made of steel, hold together reinforced concrete rail beams and ensure that the track gauge of the rail track is maintained.

In particular, longitudinal openings are made in the rail reinforced concrete beams.

In particular, spacers are installed between the bottom of the cross members and the clamping brackets.

In particular, openings are made in the cross members.

In particular, the latches are made in the form of loops.

A brief description of the drawings.

In FIG. 1 shows a General view of the module of the direct section of ballastless track.

In FIG. 2 shows a section AA of a module of a straight section of a ballastless track.

In FIG. 3 shows a section BB of the module of the direct section of the ballastless track.

In FIG. 4 is a sectional view of a module of a straight portion of a ballastless track with a lower cross member.

In FIG. 5 is a general view of the ballastless rail crossing module.

In FIG. 6 shows a General view of the module turnout ballastless track.

In FIG. 7 shows the graphical results of the analysis of the module design on a 3D model for an example of an axial load of 20 tons.

In FIG. 8 is a graphical representation of the internal stresses in the structural elements of the module.

The drawings indicate: 1 - embankment, 2 - rail reinforced concrete beams, 3 - longitudinal holes, 4 - clamping brackets, 5 - crossbars, 6 - clamps, 7 - rails, 8 - reinforcement cage, 9 - concrete, 10 - geotextile sheath, 11 - supporting plates, 12 - connecting elements, 13 - hinges, 14 - elastic linings, 15 - holes in the cross members, 16 - spacer elements, 17 - reinforced concrete beams, 18 - reinforced concrete slabs, 19 - transitional rail reinforced concrete beam, 20 - transitional rail, 21 - rail emphasis.

The implementation of the invention

The ballastless rail module contains reinforced concrete rail girders 2 with a length of 3 to 6 meters in a geotextile sheath 10, on which U-shaped clamping brackets 4 are installed at a given step, made in shape and size of the base and side walls of the rail girders 2, on top of the clamping brackets 4 In the plane formed by the upper parts of the rail beams 2, support plates 11 are installed, which are attached from the inside by connecting elements 12 to the side walls of the brackets 4, while some brackets 4 are mounted the cross members 5, on top of the support plates 11 loops 13 are installed, between which along the entire length of the rail beams 2 are laid elastic gaskets 14, on top of which the rails 7 are installed, while the loops 13 are installed in the loops 13, which are made to press the soles of the rail 7 against the elastic gaskets 14. Between the lower part of the cross members 5 and the clamping brackets 4 spacers 16 are installed.

In alternative embodiments of the module, holes 15 can be made in the cross members 5, and longitudinal holes 3 in the beams 2. In addition, the cross members 5 (see Fig. 4) can be mounted from the bottom of the brackets 4.

In accordance with the present invention, the module can be made for a section of a straight section of a railway track, for a section of a track with a radius of curvature, for an arrow section of a track, or for a crossing section of a track.

Modules for straight sections of the railway track (see Fig. 1) or for radius sections of the track can work with Pandrol, Unit Rail or Vossloh rail installation systems, and can also be manufactured for standard gauge 1435 mm and narrow gauge 1067 mm or 1000 mm At the same time, they can easily be transformed to any other gauge, rail installation systems and axial loads.

The module for the crossing section of the track additionally contains (see Fig. 5) reinforced concrete beams 17, which are installed between the cross members 5 along the rail 7, while reinforced concrete slabs 18 are installed on top and across the beams 17 so that the upper surface of these plates is in the plane of the upper rail parts 7.

These modules can be made using molded inserts 17 and 19, while the modules can work with Pandrol, Unit Rail or Vossloh rail mounting systems, and can also be made for standard gauge 1435 mm or 1524 mm and narrow gauge 1067 mm.

The turnout module (see Fig. 6) contains reinforced concrete rail beams 2, between which an X-shaped transition rail reinforced concrete beam 19 is installed, on which the transition rail 20 is installed, while on the inside of the rail 7 in the installation location of the transition rail 20 are located rail stops 21.

These modules can be used for both left and right turns, work with structures like UIC and VAE for ratios 1: 9, 1:12 and 1:20 of tangential and secant turnouts. They can work with Pandrol, Unit Rail or Vossloh rail mounting systems, and can also be made for standard gauge 1435 mm or 1524 mm and narrow gauge 1067 mm.

The arrangement of these modules is based on a mechanical theory describing the behavior of beams on an elastic base, so in FIG. 7 presents graphical results of the analysis of the module design on a 3D model for an example of an axial load of 20 tons, with FIG. 8 is a graphical representation of the internal stresses in the structural elements of the module, which allow the modules to operate at rated load without changing geometric parameters for a long time.

The technical result of the invention is the reduction of material consumption, as well as ensuring high accuracy and stability of geometric parameters is achieved through the use of longitudinal under-rail reinforced concrete beams 2 and cross-members 5 of optimal geometry and dimensions.

The manufacture of the inventive ballastless rail using modules proceeds technologically in two stages: casting and assembling the modules in a concrete plant or a special section and laying the finished modules along the track, while special equipment and sophisticated technology are not required, the modules are manufactured separately from construction work and does not directly affect the schedule for their implementation.

For the above embodiments, the methods of manufacturing modules of ballastless rail are characterized by the fact that geotextile sheaths 10 are put on reinforcing cages 8 of reinforced concrete beams, on which clamping brackets 4 with supporting plates 11 and loops 13 are mounted for mounting rail 7, as well as clamping brackets 4, between which steel cross members 5 are installed, after which they place the module blank upside down in a steel mold, close it with a lid and pump it of the mold with a concrete pump in a geotextile sheath 10 concrete mix, hold the module in the mold until the concrete mix hardens, then remove the module from the mold and turn it over, then between the loops 13 of the rail beams 2, elastic gaskets 14 are placed on which the rails 7 are installed, and then hinge 13 insert the clips 6 and set them so that the clips 6 pressed the soles of the rail 7 to the elastic gasket 14.

This method of manufacturing modules can be automated, while the cost and complexity of manufacturing will be significantly reduced.

For the manufacture of ballastless track, the finished modules are laid on the embankment 1 and the rails 7 are connected.

The use of geotextile sheath reduces the impact of harmful environmental factors (precipitation, moisture, ultraviolet radiation, etc.) on reinforced concrete beams 2, while the elastic gasket 14 reduces shock loads on the beams 2, due to this the technical result of the invention is achieved - ensuring high strength values and elasticity, ensuring stability of the geometry of the path.

The design of the modules is a unique system, the main differences of which are as follows: the modules occupy the entire space from the embankment cushion to the rail head, the stability of geometric parameters is achieved in the factory during the casting of the modules in special molds made by laser processing with an accuracy of 1 mm, the modules straight sections and corner sections up to 5.9 m long, as well as sectional turnouts can be transported along public roads, railways and in steiners.

The design of the modules provides: preservation of the geometric parameters of the path: deviations from the vertical less than 2 mm, deviations from the horizontal less than 1 mm, there is no longitudinal creep (the difference in the rolling speeds of the wheel and flanges in the longitudinal direction).

The continuous support of the rail 7 on the beams 2 allows the use of a rail of lower mass for the same load, while the waviness of the rail is reduced, there are no vertical bends of the rails 7 in the area of the turns of the track and arrows, the loads are evenly distributed along the length of several connected rails 7.

For rolling stock, the modules provide minimal longitudinal swing of the bogies (there is no deflection of the rail between the sleepers), while energy consumption is reduced, wheel wear is reduced due to the constant angle of the rail at bends, track stability reduces dynamic loads on the rolling stock (pitch and vertical swing).

Claims (10)

1. A method of manufacturing a ballastless rail module, characterized in that the reinforcing frame of the rail reinforced concrete beams is turned upside down in the mold, the mold is filled with concrete, the mold is held in shape until the concrete mix hardens, then the module is taken out of the mold and turned over, from above rails and fixers are installed on the beams, with which the rail soles are pressed, characterized in that geotextile casings are put on reinforcing cages of rail-reinforced concrete beams, on which e with a given step and alternation, wear clamping brackets with support plates and loops for fastening the rails, as well as clamping brackets between which steel cross members are installed, after which they lay the module blank upside down in a steel mold, cover it with a lid and pump it from the end of the mold with a concrete pump in geotextile casings, the concrete mixture is held in the mold module until the concrete mixture has hardened, then the module is taken out of the mold and turned over, then elastic wires are placed between the loops of the rail beams masonry, into which installed rails and then inserted into the loops and locks them is set so that the clips pressed against the rail foot to the elastic gasket. 2. The method according to p. 1, characterized in that a self-compacting concrete mixture with a fine filler is injected into the geotextile sheath. 3. Module ballastless railway track containing reinforced concrete rail beams, between which the cross members are installed, support plates are mounted on top of the rails, on which the rails are installed, while on the support plates are mounted clamps that can press the rail soles, characterized in that the reinforced concrete rail rails made from 3 to 6 meters in length in a geotextile shell, on which U-shaped clamping brackets are installed with a given step, made in the shape and size of the base and side the supporting walls of the rail beams, on top of the clamps in the plane formed by the upper parts of the rail beams, support plates are installed, which are attached to the side walls of the brackets by connecting elements on the inside, with crossbars between some brackets, loops on top of the support plates, between which along full length of rails elastic gaskets, on top of which the rails are installed, while the tabs are installed in the hinges. 4. The module according to claim 3, characterized in that the length of the rail corresponds to the length of reinforced concrete rail beams. 5. The module according to claim 3, characterized in that the cross-members are made of steel, hold together rail reinforced concrete beams and ensure compliance with the track gauge of the rail track. 6. The module according to claim 3, characterized in that longitudinal openings are made in the rail reinforced concrete beams. 7. The module according to claim 3, characterized in that spacers are installed between the lower part of the cross members and the clamping brackets. 8. The module according to claim 3, characterized in that the openings are made in the cross members. 9. The module according to claim 3, characterized in that the latches are made in the form of loops.

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