RU2756929C1 - Sleeper pad and method for its manufacture, construction of railway sleeper with sleeper pad fixed in it and method for connecting sleeper pad with railway sleeper - Google Patents

Abstract

FIELD: track superstructure elements.SUBSTANCE: inventions group relates to the field of elements of the superstructure of the track, in particular to sleeper pads, methods for their manufacture, concrete sleepers containing such a lining, and methods for manufacturing concrete sleepers with lining. The lining contains two polymer layers and vertical projections. The rigidity of the polymer layers is different. The protrusions are made in the form of mushroom-shaped bodies of revolution. All transition areas of the protrusions are rounded. Two through holes are made in the middle part of the gasket. The molding of the protrusions and the connection of the lining layers are carried out in one process. In the manufacture of the sleepers, the concrete mass is poured into a mold. Two embedded elements are installed in the sleeper. The position of the embedded elements corresponds to the position of the holes in the backing. The lining is oriented according to the embedded elements and embedded in concrete. Vibration compaction of concrete is carried out under load through the lining.EFFECT: increased reliability and durability of the sleeper-lining connection.12 cl, 6 dwg

Description

The present group of inventions relates to a sleeper pad (shock absorber) designed to cushion the sleeper during the passage of a railway train in order to extend the life cycle of the ballast layer by reducing the rigidity of the rail base and reducing the pressure on the ballast, which is attached from the sole of the sleeper, in particular, the sole concrete or reinforced concrete sleepers resting on the ballast layer (ballast prism), as well as to the method of making the sleeper pad, to the device of the railway sleeper with the sleeper pad fixed in it and the method of connecting the sleeper pad to the railway sleeper.

The ballast layer refers to the upper structure of the track, as a rule, it consists of crushed stone and / or gravel and is designed to absorb pressure from sleepers, to which, in turn, through intermediate fasteners and rails, transfer the load of the rolling stock wheel, and distribute as evenly this is the pressure on the surface of the roadbed, serve as a bonding medium for individual sleepers in order to resist horizontal forces that appear in the track when the train moves both along the track (track hijacking) and across the track (track shift), drain water from the track surface after rains and melting snow. The presence of sleeper pads allows damping the dynamic additions of inertia forces arising from the movement of rolling stock on rails due to the presence of continuous and isolated irregularities in the track and wheels, increase the comfort of passengers passing in the train and reduce ballast pollution due to wear and chipping of rubbing rubble.

A sleeper pad, also referred to as a sleeper pad and sleeper damper, is an elastic layer that belongs to the upper structure of the railway track and is located on the underside of the railway sleeper on the ballast layer.

The sleeper pad provides the ability to adapt to the surface of the ballast layer by partially pressing the gravel into the pad. Due to this, the contact area of the load-bearing surface increases, and the contact stresses in the ballast particles (crushed stone) decrease. In particular, the compressive stresses in the ballast can be reduced, especially in the area of its contact with the sleeper, since the contact surface area is increased due to the pressing of the crushed stone particles into the sleep absorber. In addition, due to the pressing of crushed stone particles into the sleeper shock absorber, the shear resistance of the sleeper in the horizontal plane increases.

Known gaskets for a sleeper, containing elongated (for the entire width of the gasket) symmetrical protrusions located on the flat surface of the gasket perpendicular to the base, the surface of which in cross-section has a mushroom profile (US patent 7278588, publ. 11.05.2006) [1], (patent document DE 102004011610 A1, publ. 09/29/2005) [2],

The disadvantage of these gaskets is the shape of the protrusions, which does not make it possible to increase the closed geometric connection with the sole of the sleeper in all directions, and therefore in the direction of the axis of the protrusions equidistant from the height and width of the protrusions, adhesion to the sleeper is carried out only due to adhesion. In addition, the junction of the leg of the elongated mushroom-shaped protrusion with the flat surface of the gasket forms a right angle, which is a stress concentrator that reduces the durability of the gasket.

Known gasket for a sleeper, containing elongated protrusions located on the flat surface of the gasket perpendicular to the base, the surface of which in cross-section has a mushroom profile (patent document EP 1186709 B1, publ. 13.03.2002) [3].

The disadvantage of these gaskets is the shape of the protrusions, similar to a harpoon with sharp ends on the sides, which is a stress concentrate in concrete, which reduces the durability of the sleeper itself, in which these protrusions are fixed. In addition, the specified shape does not create a closed geometric connection with the sole of the sleeper in all directions, and therefore in the direction of the axis of the projections equidistant from the height and width of the projections, adhesion to the sleeper is carried out only due to adhesion.

Hereinafter, concrete is understood as a product containing concrete, including reinforced concrete.

Known sleeper pad containing through holes located on the flat surface of the pad (utility model RU 188195, publ. 02.04.2019) [4].

According to the description, the presence of holes prevents the gasket from displacing and slipping out from under the sleeper, due to the fact that the gasket holes correspond to the minimum size of the fraction of crushed stone used for the ballast layer of railways, crushed stone, getting into the gasket holes and getting stuck in them, prevents its displacement in the horizontal plane and at the same time does not require special fastening to the sleeper, for example, in the form of gluing, fastening to the sleeper with various special devices, fastening by changing the design of the sleeper, etc.

These holes in relation to the holes in the proposed gasket have a different purpose. They are designed to hold the lining on the surface of the ballast layer (ballast prism) due to the entry of the elements of this layer into the gasket holes.

Of course, the holes in the proposed gasket can also prevent the gasket from displacing relative to the ballast layer, but their main purpose is to quickly and accurately orient the gasket relative to the contour of the concrete surface in the process of connecting the gasket to the tie.

The disadvantage of this design of the sleeper pad is precisely the absence of fastening elements to the sleeper, which can lead to its displacement and a decrease in its depreciation properties during the operation of the track and, in particular, during its periodic straightening.

Known is a sleeper pad intended for connection with a sleeper, made in the form of a two-layer (two-component) polymer plate, the layers of which are interconnected, containing in one layer vertically arranged fastening elements intended for geometric locking and adhesive adhesion to the sleeper, in which fastening elements are made in the form of mushroom-shaped bodies of revolution, in which the leg of each fastening element contains two smoothly expanding concave sections in the direction of the support and head part of the fastening element, conjugated with a cylindrical section located between them, located above a conical surface section with an inverse cone, conjugated with a smoothly widening concave section located closer to the upper part of the leg, having a flat section on the upper part (patent DE 69714932 T2, publ. 30.09.1997) [5].

The disadvantage of this device is the presence on the fastening elements of a circular sharp edge formed by a conical surface with an inverse cone and a flat surface of the upper part, which creates a stress concentrator in a concrete sleeper; the bodies of the fastening elements are hollow, which complicates their manufacture and prevents the formation of a protrusion in the central part of the top flat area of the surface, as well as the absence of holes for orientation of the sleeper pad during its connection with the concrete sleeper.

A known method of manufacturing a strip for a railway sleeper, in which a reinforcing layer is located between the first elastic layer and the second elastic layer, while the second elastic layer forms the outer surface of the strip, and the reinforcing layer contains fibrous material (patent AT 506529 B1, publ. 05/15/2010) [6].

The disadvantage of this method is the high labor intensity, the presence of time-consuming costs and additional production costs associated with the multistage process, including the manufacture of two layers of gaskets and their subsequent connection with a reinforcing layer containing fibrous material, as well as the very presence of an additional reinforcing layer, which increases the cost of the sleeper pad ...

Known is a sleeper shock absorber for a railway sleeper resting on a ballast prism containing a first layer and a second layer, the first layer being located in or on the second layer and forming a clutch system designed to align and connect with a railway sleeper, wherein the first layer contains a profiled element, which is equipped with at least one recess, and in the installed position on the railway sleeper, the profiled elements are elongated in the direction of the rail track or at an angle to the rail track lying in the range of 30 -60 ° (see patent RU 2704761 C1, publ. 30.10. 2019) [7].

A similar design is described in the patent for invention AT 505117 B1 [8].

From [7], there is also known a method for producing a sleep absorber (pad) comprising a first layer and a second layer, the first layer forming a clutch system intended for alignment / connection with a railway sleeper, and the first layer is formed by a plurality of profiled elements, which are provided with at least at least one recess, and the profiled elements pass in the direction of the rail track or at an angle to the rail track lying in the range of 30-60 °, while the length of the recess of the profiled element in the longitudinal direction exceeds the length of the profiled element in the transverse direction perpendicular to the longitudinal direction, when This said method includes the following stages:

- preparation of the first layer;

- preparation of the second layer;

- alignment and connection of profiled elements with the second layer.

The preparation of the shaped element may involve cutting or punching it out of a plate, for example by casting or extrusion. In particular, it is provided that the recesses are cut out in the profiled element. The recesses pressed in this way can advantageously be used as a clutch system in the finished sleeper damper. Moreover, during the manufacture of the sleeper damper or during the feeding of the sleeper damper, such recesses can be effectively used to feed the profiled member or the sleeper damper, for example, by means of feeding means engaging with the recesses and the supplied profiling element or the sleeper damper. The connection can be carried out, for example, by pressing, in particular by continuous or discontinuous pressing of two layers. According to one embodiment of the disclosed invention, the vulcanization of the first and / or second layer is performed during or after pressing.

The at least two-layer construction provides the advantage that it allows two layers to be obtained -

and, in particular, to perform various manipulations with them - separately, and this greatly simplifies the technology for the production of the sleeper shock absorber.

The disadvantage of this method is the complexity of manufacturing, in which, to obtain closed-form profile elements, workpieces in the form of strips are used, in each of which they are cut or cut or otherwise made through holes, with the subsequent connection of the strips to each other, which leads to a multistage process, requires additional devices for punching or cutting through transverse holes and operations for eliminating or reducing stress concentration in concrete by smoothing out sharp areas of the form between the hole and the outer surface of the protrusions.

According to the description [7], the protrusions that form a positive fit with the concrete of the sleeper can have other shapes, for example, a T-beam or an I-beam, corrugated or zigzag. According to the description of one of the embodiments of the invention [7], it is provided that the profiled element, in addition to the presence of a recess, is characterized by the presence of an end seal in the form of a vault, mushroom-shaped and / or curved at its end facing away from the first layer, wherein the recesses are characterized by a substantially square, arcuate and rounded shape.

The description of the specific shape of the protrusions, allowing them to be performed simultaneously with the formation of layers and their adhesion to each other without additional operations, is absent in [7].

In the description [7] there are also no through technological holes in the gasket, which ensure the orientation of this gasket relative to the concrete sleeper with the help of metal embedded elements, which provide a reduction in the time for its orientation relative to the sole of the concrete sleeper, and shear fixation when connected to the sleeper, especially during its manufacturing.

Known is a reinforced concrete sleeper having elastic elements made of polymer material located on the sole of the sleeper in its under-rail parts, in which the elastic elements are made in the form of gaskets fixed in the sleeper by embedding them into fresh concrete during the molding of sleepers (see utility model patent RU 76649 U1, publ. 09/27/2008) [9].

From the drawing [9] follows the presence of two through holes passing through the polymer material and the concrete of the sleepers. Information on the purpose of these holes is not contained in [9]. It can only be assumed, given that they pass vertically through the body of the concrete sleeper, that they are designed to reduce moisture in the ballast layer by ventilation.

The disadvantages [9] include the lack of form-fit in the connection of the gasket with the sleeper, which leads to a decrease in the durability of the gasket.

It is also known that, during pressing or injection molding, a high polymer elastic material obtains a geometric surface modification as its original shape. To this end, in the process of pressing or injection molding, spike and / or ribbed protuberances are formed from the high-polymer elastic material. After cooling, the high polymer elastic material with spikes and / or ribs is processed with a hot stamping tool. The spike and / or ribbed eminences, which are approximately vertical, are pressed with a hot molding tool and thus deform the spike and / or ribbed eminences into mushroom and / or T-shaped and / or curved eminences. Due to the low pressure of the hot stamping tool, the elevations in the upper part get a larger diameter (see patent DE 10 2004 011 610 A1, publ. 09/29/2005) [10].

According to [10], in the process of pressing or injection molding, a high-polymer elastic material receives a geometric modification of the surface as an initial shape. To this end, in the process of pressing or injection molding, spike and / or ribbed protuberances are formed from the high-polymer elastic material. After cooling the high polymer elastic material with spikes and / or ribbed bumps, it is processed with a hot stamping tool. The spike and / or ribbed eminences, located approximately vertically, are pressed by lightly compressed pressure with a hot molding tool and, thus, deforms the spike and / or ribbed eminences into mushroom and / or T-shaped and / or curved eminences. Due to the light pressure of the hot stamping tool, the elevations in the upper part are obtained with a larger diameter. When the high polymer resilient material made by this method is bonded to concrete so that it can freely penetrate between all elevations, a composite system is created that ensures that, after the concrete has cured, a strong bond between the high polymer resilient material and the concrete is created.

The disadvantages [10] in relation to the sleeper pad include the fact that it is single-layer, which makes it impossible to select a high-polymer elastic material with such rigidity to ensure at the same time its vibration resistance to vibrations during the passage of the train, the reliability and durability of the support on the ballast layer ...

In addition, the disadvantages [10] include the fact that the mushroom-shaped protrusions at the base contain a right or acute angle, which creates a stress concentration in the gasket in these places, which reduces its durability, and the absence of two holes in the gasket leads to an increase in the time of its orientation into position for introduction into a concrete semi-liquid or liquid mass, while in the process of introduction, in the absence of holes in the gasket and embedded elements in the concrete mass, the gasket may shift relative to its design position.

The closest analogue of the device and method for manufacturing a sleeper pad, as well as the device for a sleeper pad with a sleeper pad and a method for connecting a sleeper pad with a concrete sleeper, are the devices and methods described in [9].

The technical problem of the claimed invention is to create a sleeper pad, intended, in particular, for a railway sleeper resting on a ballast prism, a method for producing a sleeper pad, creating a railway sleeper connected to a sleeper pad, as well as a method of connecting it to a railway sleeper containing concrete , in which the indicated disadvantages of analogs are eliminated.

The technical result of the invention consists in increasing the reliability, durability of the connection of the sleeper pad with the sleeper and in increasing the productivity in its manufacture and connection with the sleeper, due to the absence of protrusions and transition surfaces between the protrusions and the surface of the gasket on which they are located, on the surfaces, without rounded corners, and also due to the presence of two holes in the gasket for orientation relative to the concrete mass of the sleeper in the design position and fixing it in this position during vibration compaction of the concrete mass under load through the gasket, ensuring that it cannot be displaced from this position until the finished composite product is obtained.

The technical result of the invention in relation to the method of manufacturing a two-component sleeper pad is to increase productivity by combining in one process of molding the protrusions and joining the layers of the pad.

The technical result of the invention in relation to the method of manufacturing a concrete sleeper with a sleeper pad is also to increase the productivity and quality of the connection due to the orientation of the pad relative to the contour of the concrete mass using two holes in the sleeper pad, designed to orient the pad relative to the concrete mass using embedded elements in it, located at a distance and equal to the center distance in the gasket, and having external dimensions corresponding to the diameter of these holes, thereby ensuring that the gasket cannot be displaced relative to the design position during the insertion of the gasket into the concrete mass and vibration compaction of concrete with a load through the gasket.

FIG. 1 shows a general view of the sleeper pad from the side of the projections (in perspective).

FIG. 2 - an enlarged fragment of the sleeper pad from the side of the projections.

FIG. 3 is a drawing of the sleeper pad (view from the side of the projections).

FIG. 4 is a drawing of the sleeper pad (view from the side without protrusions).

FIG. 5 is a drawing of the protrusion with the dimensions of the radii of the roundings.

FIG. 6 - drawings of projections with dimensions, depending on the location.

Sleeper pad 1 consists of a polymeric two-layer material (two-component) and is designed to be connected to the sleeper. Adjacent layers of the gasket are interconnected and differ in the degree of rigidity.

One layer contains vertically located protrusions 2 made in the form of mushroom-shaped bodies of revolution. The transition areas of the surfaces of each protrusion from one body of revolution to another on all surfaces, as well as in the transition areas between the protrusions and the surface of the gasket, on which they are located, are made rounded (Figs. 2, 5 and 6). The protrusions are made monolithic, rounded transition sections are made on all transition sections, including the upper and lower parts of the protrusions, as well as on the transition sections between the bases of the protrusions and the surface on which they are located. In the middle part of the gasket, two through holes 3 are made along the long side.

The layer containing vertically located protrusions is designed to dampen vibrations arising from the movement of the rolling stock.

The layer free of ridges is designed to adhere to the ballast and has a stiffness sufficient to protect the layer with ridges and the concrete sleeper from the impact of sharp edges of chippings.

The sleeper pad can be rectangular or rectangular on one side and trapezoidal on the other, depending on the shape of the sleeper's bearing surface.

The distances between the projections on the rectangular section of the spacer are the same, with all the dimensions of the projections in height and the side dimensions for all the projections the same, that is, the projections are made identical.

On the trapezoidal section of the gasket, with the exception of the height, the dimensions are made stepwise decreasing in proportion to the decrease in the width of the trapezoidal section.

The optimal number of projections per 100 cm2 of the gasket to achieve the maximum technical result is 23 pieces, which are evenly distributed on the rectangular surface of the gasket.

The length of the gasket is in the range of 450-1350 mm, the width is 250-300 mm, the thickness, excluding the protrusions, is 4-50 mm.

The polymer layer, free from protrusions, has a stiffness value corresponding to the nominal static modulus of elasticity in the range from 0.05 to 2 N / mm3, which corresponds to the bed coefficient kgf / m3.

The formation of the protrusions and the connection of the layers are carried out in one process. For this, a form with pull-out elements is used to form mushroom-shaped protrusions.

Layer blanks are placed in the mold in the form of two raw materials (prepared sheets of polymer blanks, previously obtained in a mixer and rolled on rollers), then the mold is closed and under certain pressure and temperature, which are determined experimentally, depending on the polymer materials used, by heating the material the process of connecting sheets to each other is started with the simultaneous formation of mushroom-shaped protrusions.

After the end of the process of formation and connection, the upper part of the mold is lifted, while the retractable elements forming the mushroom-shaped protrusions at the beginning of the rise remain together with the formed protrusions in the lower part of the mold. In the process of lifting the upper part of the mold, these sliding elements move apart in the transverse direction, ensuring the release of the protrusions from them. After that, the upper part of the mold is stopped and the pull-out elements are raised to the upper part of the mold until they are tightly connected with each other and the upper part of the mold.

The finished product is removed, the following blanks are placed in the mold, after which I move the upper part of the mold down. In this case, the elements that form the mushroom-shaped protrusions remain stationary until they move into the recesses of the mold. After that, the elements that form the mushroom-like protrusions move with the upper part of the mold.

Desirably, the surfaces of the recesses have the same shape as the outer surfaces of the mushroom-shaped protrusions. Most preferably, these surfaces are made in the form of a truncated cone, and the elements forming the mushroom-like protrusions consist of at least two axisymmetric parts.

The holes 3 for orienting the gasket and keeping it from displacement during penetration into concrete can be made by cutting or in the form - simultaneously with the formation of the gasket, by making them in the form of protrusions to form these holes.

The manufacture of a concrete sleeper with a sleeper pad is carried out as follows.

In the mold for the manufacture of sleepers set at a distance from each other, corresponding to the distance between the holes 3 in the gasket, two embedded elements of such a length that they protrude above the concrete surface, concrete mass is poured into the mold, the gasket is oriented by putting holes 3 on the protruding ends.

Claims (12)

1. A double-layer polymeric sleeper pad, intended for connection with a sleeper, the adjacent layers of which are interconnected and differ in rigidity, containing vertically located protrusions in the outer layer, made in the form of mushroom-shaped bodies of revolution, transitional sections from one body of revolution to another on each the protrusion is made rounded, characterized in that the protrusions are made monolithic, the rounded transition sections are made on all transition sections, while in the middle part of the gasket along the long side there are two through holes designed to orient the gasket relative to the sleeper during the connection of the concrete sleeper with the sleeper pad. 2. Sleeper pad according to claim 1, characterized in that it is rectangular. 3. A sleeper pad according to claim 1, characterized in that it is rectangular on one side and trapezoidal on the other. 4. A sleeper pad according to claim 3, characterized in that the distance between the projections on the trapezoidal section and the dimensions of the projections, with the exception of the height, are made stepwise decreasing in proportion to the decrease in the width of the trapezoidal section. 5. Sleeper pad according to claim 1, characterized in that the number of projections per 100 cm ² pad is 23 pieces, which are evenly distributed on the rectangular surface of the pad. 6. A sleeper pad according to claim 1, characterized in that its length is in the range of 450-1350 mm, width - 250-300 mm, thickness, excluding protrusions, - 4-50 mm. 7. A sleeper pad according to claim 1, characterized in that the polymer layer free of protrusions has a degree of rigidity corresponding to the nominal static modulus of elasticity in the range from 0.05 to 2 N / mm ³ . 8. A method of manufacturing a two-component sleeper pad, including molding the protrusions and connecting the layers to each other, characterized in that the molding of the protrusions and the bonding of the layers are performed in one process. 9. A concrete sleeper made in one piece with a sleeper pad made of a polymeric two-layer material, the adjacent layers of which are interconnected and differ in rigidity, containing vertically located protrusions made in the form of mushroom-shaped bodies of revolution, in which transition sections from one body of revolution to the other on each protrusion are made rounded, while the fastening of the gasket with the tie is made by introducing the protrusions into the concrete mass, characterized in that the protrusions are monolithic, the rounded transition sections are made on all transition sections, including the transition sections between the base of the protrusions and the surface of the gasket, on which they are located, and in the middle part of the gasket along the long side, two through technological holes are made, used to orient the gasket relative to the sleeper in the process of connecting the concrete sleeper with the sleeper pad. 10. A method of manufacturing a concrete sleeper with a sleeper pad, in which the concrete mass is poured into a mold, the gasket is oriented and inserted into the concrete mass with protrusions forward, characterized in that, before the orientation of the gasket into the concrete mass, it is set at a distance from each other corresponding to the distance between the holes in gasket, two embedded elements protruding above the concrete surface, while the gasket is oriented by putting holes on the protruding ends of the embedded elements, and after the introduction of the protrusions into the liquid concrete, concrete is vibrated under load through the gasket. 11. A method of manufacturing a reinforced concrete sleeper with gaskets, according to claim 10, characterized in that the distance from the edge of the gasket to the lateral edges of the foot of the sleeper is maintained in the range from 5 to 10 mm, from the end edges to the ends of the sleeper - from 5 to 15 mm. 12. A method of manufacturing reinforced concrete sleepers with gaskets according to claim 10, characterized in that in the process of vibration compaction of concrete, the gasket is immersed in concrete 2 mm deep from the surface of the sleeper.

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