RU2761484C1 - Automated complex for assembling rail-sleeper grid of railway track - Google Patents

Abstract

FIELD: railway construction.

SUBSTANCE: invention relates to the field of construction of the upper structure of a railway track, in particular to automated complexes for assembling a rail-sleeper grid. The complex uses sleepers, pre-equipped with elements of rail fasteners. The complex contains a crane for installing sleepers installed in series, a sleeper feed conveyor with a sleeper layout device, a sleeper density conveyor, an assembly conveyor with a rail installer, a crane for shipping rail-sleeper grid links installed sequentially. The complex is equipped with devices for dismantling or transferring elements of rail fasteners on sleepers to the mounting position, as well as mounting rail fasteners. Dismantling or transfer to the mounting position of the fasteners is carried out when the sleepers are located on the sleeper density conveyor. The fasteners are installed when the sleepers are located on the assembly line. The mounting and dismounting devices are made in the form of a hinged robot manipulator. The robot has a multi-position grip for influencing the elements of rail fasteners.

EFFECT: productivity of the assembly process of the rail-sleeper grid links is increased.

11 cl, 5 dwg, 2 ex

Description

Technology area

The invention relates to the field of assembly of rails and sleepers (links), namely to an automated complex for the assembly of rails and sleepers (hereinafter referred to as RSHR) of a railway track.

State of the art

The following solutions are known from the prior art.

A known complex for assembling a rail-and-sleep lattice of a railway track, including a crane, parallel located in the crane space, direct and reverse stands for placing link materials on them and enclosing guide stands for moving along them in the technological sequence of assembling a link of autonomous units of technological equipment. The autonomous unit, moving along the guides enclosing the stand (along the path enclosing the stand), lays out the sleepers on the stand in a row along the diagram of the link being assembled. Packages of sleepers are laid out in front of it with cranes, and in front of these cranes, the assembled link is removed and sent to the link warehouse. The complex contains an autonomous unit that unpacks the sleepers and pads in the corresponding sleeper nests, as well as a device for installing embedded assemblies in the sleeper nests and laying out the rail pads on the pads. The cranes are used to lay rails on a set of link sleepers (RU 2293813 C1, E01B 29/24, 20.02.2007).

A known complex for assembling a rail-and-sleep lattice, containing a section of a technological railway track, on which a warehouse of sleepers is sequentially located, a point for laying out sleepers according to a given diagram, points for supplying fasteners and rails to an assembly line, a point for final assembly, a point for receiving and storing assembled links, a device for performing operations on the assembly of a rail link, moving along the entire line, as well as cranes designed to deliver sleepers to a sleepers placement point according to a given diagram, to lay rails on sleepers as part of the final assembly point and to form packs of links. Laying cranes with sleeper gripping devices were used. A device for performing operations on the assembly of a rail link is made in the form of a self-propelled roller platform, on which a jig pallet is mounted with the ability to remove, equipped with a mechanism for changing the pitch of the sleepers, made in the form of two axes mounted with the possibility of rotation on the frame of the jig, on which they are rigidly fixed stops for different sizes of the spacing of the sleepers (RU 2222659 C2, E01B 29/24, 09/10/2003).

The disadvantages of such complexes are low productivity and high labor costs when assembling the links of the rail and sleepers.

There is also known an automated complex for assembling a rail-and-sleep lattice of a railway track, containing a sequentially installed crane for installing a package of sleepers on a conveyor and located on the conveyor a spreader for packages of sleepers, a device for removing wooden gaskets from sleepers, a device for leveling and adjusting the location of sleepers. The complex also contains a rail installer, equipment for the mounting section of fasteners, containing automatic devices for mounting rail fasteners (separate devices for installing rail fastening insulators, for installing terminal blocks, for installing spring terminals, for installing eccentric adjusters that press the tie to the rail and perform installation rail fastening), and a rail storage - a platform for placing the assembled links of the rail and sleepers on it and their further transportation to the storage site (RU 2285080 C1, Е01В 29/24, publication date 10.10.2006).

The disadvantage of this complex, as well as the above complexes, is that it does not provide for the use of sleepers pre-equipped with fastening elements at the manufacturer. This is due to the fact that previously the factories did not produce sleepers pre-equipped with fasteners. In the case of the theoretical use of such sleepers when assembling a rail and sleeper lattice using known complexes, it is assumed that they should be preliminary dismantled, after which, for the installation of rail fasteners, all fastening elements must be separately loaded into several different automatic fastening devices, which leads to a high overall labor intensity of the operation technology. Maintenance of such a complex requires a large number of service personnel.

The closest analogue to the claimed assembly complex for the rail and sleep grid from the prior art has not been identified.

Recently, it has become possible to manufacture sleepers by manufacturers equipped with rail fastening elements. In this regard, the technical problem of the claimed invention is to overcome the technical disadvantages inherent in analogues, which leads to the need to expand the arsenal of technical means, namely, to create a complex for assembling a rail-and-sleep lattice of a railway track on sleepers, pre-equipped with rail fastening elements, with a high degree of automation and robotization. providing low labor costs with high-quality assembly of rail and sleepers at the production bases of track machine stations (PMS) and a minimum number of maintenance personnel.

Disclosure of the essence of the invention

The technical result of the claimed invention is to increase the productivity of the assembly process of the links of the rail and sleep grid by increasing the automation and robotization of the assembly process.

The technical result is achieved by creating an automated complex for assembling a rail-and-sleep lattice of a railway track on sleepers, pre-equipped with elements of rail fasteners, containing a sequentially installed crane for installing sleepers, a sleepers feed conveyor, a diagram conveyor, an assembly conveyor with a rail installer located above it for installing rails on the assembled link and a crane for unloading the rails and sleepers. A device for laying out sleepers is installed on the conveyor for feeding sleepers, at least one device for dismantling or transferring to the installation position of the elements of rail fasteners on sleepers, pre-equipped with them, is located next to the conveyor, and at least one device for installation of elements of rail fasteners. In this case, at least one device for dismantling or transferring the elements of rail fasteners into the mounting position and / or at least one device for mounting the elements of rail fasteners is made in the form of an articulated robotic arm having a multi-position gripper for dismantling the elements of rail fasteners or converting them into mounting position and / or mounting of rail fastening elements

Due to the sequential arrangement of the conveyors and the above-mentioned devices of the complex, the most optimal assembly process is possible in a certain way.

Due to the use of sleepers during the assembly of the rail-and-sleep lattice, pre-equipped with elements of rail fasteners, it is ensured that the time spent on equipping the sleepers with fasteners as part of the technological process of assembling the rail-and-sleep lattice is eliminated.

Due to the use of articulated robotic manipulators, an increase in the automation of the process, both dismantling and assembly as a whole, is provided, which leads to an increase in the productivity of the process.

Thus, when using the claimed automated complex, an increase in the productivity of the assembly process of the links of the rail and sleep grid is achieved.

In the particular case of the implementation of the claimed invention, before the device for laying out the sleepers, the complex may additionally contain a distributor of the packages of sleepers into rows, which is used when installing the sleepers packages with a crane. In the particular case of the implementation of the claimed invention, the complex may additionally comprise a device for leveling the sleepers at the ends and a device for laying the sleepers, which ensures the receipt of the sleepers from the device for laying out the sleepers and placing them on a diagram conveyor. The sleeper laying device ensures that the sleepers are taken from the laying device, and after it is aligned by the sleeper leveling device at the ends, it is placed on a diagram conveyor installed behind it.

The diagram conveyor can preferably be made with the possibility of moving the sleepers to a predetermined step of the diagram (the step of the diagram means the distance between the sleepers).

In the particular case of the implementation of the claimed invention, the complex may additionally contain equipment for automatic measurement and control of at least one or all of the following parameters of the links of the rail and sleep grid:

- track width along the link length;

- the race of the link rails;

- the distance between the axles of the sleepers;

- electrical resistance between link rails and air temperature.

The complex may contain a device for cleaning wooden gaskets and a device for cleaning the rows of sleepers from debris and snow installed in series on the conveyor for feeding the packages of sleepers.

All conveyors are preferably chain conveyors.

The complex may contain a transporting device made in the form of a trolley for transferring the sleepers laid out along the diagram from the diagram conveyor to the assembly conveyor.

The complex may contain equipment for preliminary processing of rails and roller tables for moving rails from the warehouse to equipment for their preliminary processing, which can be used as cleaning and / or rail cutting and / or rail drilling machines and / or machines for chamfering in holes.

The rail installer may contain sensors for determining the position of the rails.

Brief Description of Drawings

The claimed invention is illustrated by the following figures, illustrating the structure of the complex in the particular case of the invention:

fig. 1 is a diagram of the location of the sections of the assembly complex for the links of the rail-and-sleep lattice of the railway track;

Fig. 2 is a general view of the assembly complex for the railroad lattice links;

fig. 3 - a device (articulated robotic arm) for dismantling the elements of rail fasteners on sleepers or bringing fasteners of sleepers to the rail installation position, located next to the device for unscrewing screws:

a) side view;

b) top view;

c) general view.

Positions indicate the following elements:

1 - section for laying sleepers;

2 - section for dismantling of track superstructure elements;

3 - section for installing rails;

4 - section for assembling track superstructure elements;

5 - section for preparation of rails;

6 - crane;

7 - conveyor for supplying packages of sleepers;

8 - packages of sleepers;

9 - sleepers warehouse;

10 - diagram conveyor;

11- conveyor for platforms with APC fastening elements;

12 - assembly conveyor;

13 - rail installer;

14 - cranes for unloading the links of the rail and sleepers;

15 - device for cleaning packages of sleepers from snow and debris;

16 - distributor of packages of sleepers into rows;

17 - device for cleaning wooden pads;

18 - device for cleaning the rows of sleepers from snow and debris;

19 - device for laying out sleepers;

20 - device for laying sleepers;

21 - a device for leveling sleepers at the ends;

22 - device for dismantling elements of rail fasteners on sleepers or bringing fasteners of sleepers to the position of rail installation, made in the form of an articulated robot-manipulator;

23 - device for mounting elements of rail fasteners, made in the form of an articulated robotic arm;

24 - equipment for automatic measurement and control of the track gauge along the link length, the run of the link rails, the distance between the axles of the sleepers, electrical resistance and air temperature;

25 - cart;

26 - equipment for preliminary processing of rails;

27 - roller tables for moving rails from the warehouse of rails to equipment 26 for their preliminary processing;

28 - rail warehouse;

29 - rail installer;

30 - roller tables for receiving processed rails and transferring them to the transverse conveyor-accumulator of rails;

31 - storage conveyor;

32 - rail roller tables;

33 - bunker for wooden gaskets;

34 - bin for rubbish and snow;

35 - belt conveyor;

36 - belt conveyor;

37 - device for unscrewing screws (screwdriver);

38 - device for screwing screws (screwdriver).

The automated complex can be divided into separate functional sections: section for laying sleepers 1, section for dismantling elements of track superstructure 2, section for installing rails 3, section for assembling elements of superstructure of track 4 and section for preparing rails 5 (Fig. 1).

The equipment of the complex is located at the production base. The complex contains a crane 6, a conveyor 7 for feeding packages of sleepers 8 from a warehouse of sleepers 9, a diagram conveyor 10, a conveyor 11 for platforms with APC fastening elements (located next to the left and right of the diagram conveyor 10), an assembly conveyor 12 with a rail installer located above it 13 for installation of rails on the assembled link and cranes 14 for shipping the links of the rail and sleepers (figure 2). On the conveyor 7 for feeding sleeper packages 8, a device 15 is installed for cleaning sleepers packages from snow and debris, a spreader 16 packages of sleepers 8 into rows, a device 17 for cleaning wooden pads, a device 18 for cleaning sleepers rows from snow and debris, a device 19 for laying out sleepers, a stacking device 20 sleepers and a device 21 for leveling sleepers at the ends (aligning the axis of the sleeper with the axis of the link).

Above the diagram conveyor 10 in front of the rail installer 13, four devices 22 are fixed on the portal frame for dismantling the elements of the rail fasteners on the sleepers or bringing the fasteners of the sleepers to the position of the rail installation, each of which is made in the form of an articulated robotic manipulator with a multi-position gripper (Fig. 3). Above the assembly conveyor 10 behind the rail installer 13, four devices 23 are also fixed on the portal frame for mounting rail fastening elements (fastening fastening elements after installing the rails), each of which is made in the form of an articulated robotic manipulator with a multi-position gripper.

The complex contains equipment 24 for automatic measurement and control of the aggregate track width along the link length, the run of the link rails, the distance between the axles of the sleepers, electrical resistance and air temperature.

The complex contains a trolley 25 for transferring the sleepers laid out along the diagram from the diagram conveyor 10 to the assembly conveyor 12.

The complex contains equipment 26 for preliminary processing of rails, which can be used as cleaning machines, rail cutting machines, rail drilling machines, machines for chamfering in holes, and roller tables 27 for moving rails from the rails warehouse 28 to equipment 26 for their preliminary processing. Above the rail warehouse 28, a rail installer 29 is installed. Next to the equipment 24, roller tables 30 are also located for receiving processed rails and transferring them to the transverse storage conveyor of rails 31. Next to the storage conveyor 31, under the rail installer 13, there are rail roller tables 32.

The zone for feeding the packages of sleepers 8 to the conveyor 7 at the section for laying out the sleepers is served by a gantry crane 6 with a lifting capacity of 10 tons.

The exit area of the assembled link and the operational warehouse of the RSHR links are served by two gantry cranes 14 with a lifting capacity of 10 tons each.

In the section 1 for laying out the sleepers, the conveyor 7 for feeding the packages of sleepers consists of successively installed chain conveyors.

In addition, the complex contains a bunker 33, into which wooden gaskets are dropped by a device 17 for cleaning wooden gaskets, and bunkers 34, into which scraped snow and debris are dumped by means of belt conveyors 35 and 36.

When working with sleepers equipped with ZhBR and W30 fasteners, a screwdriver 37 is used to unscrew the screws and a screwdriver 38 for screwing in screws (at the site of dismantling and installation, respectively), each of which is installed on a separate portal frame next to articulated robotic manipulators 22 (Fig. 3).

Implementation of the invention

In the particular case of the implementation of the invention, the complex operates as follows.

In section 1 of the laying of sleepers by a gantry crane 6, the packages of sleepers 8 are fed from the warehouse of sleepers 9 to the conveyor for supplying sleepers 7. Then the package of sleepers 8 is sequentially moved by the conveyor 7 under the cleaning device 15, where the top row of the package is cleaned from snow and debris and into the action zone a spreader of 16 packages of sleepers per row.

After laying the sleepers into rows, they move to the position of the device 17 for cleaning wooden gaskets, where the row stops and the gaskets are dropped by the device 17 into the bunkers 33. Then the row of sleepers moves to the position of cleaning the sleepers with the device 18. The cleaned snow and debris are removed by the belt conveyor 35 into the bunker for garbage 34. Next, the row of sleepers moves to the position of the sleeper layout device 19, which separates the sleepers one by one from the rows and transfers the sleepers from the conveyor 7 to the sleeper stacker 20, where the sleepers are aligned at the ends relative to the longitudinal axis of the complex by the device 21, after which the transfer takes place sleepers on a diagram conveyor 10 for section 2 of dismantling elements of the superstructure of the track. Garbage, which is formed as a result of leveling and shifting the sleepers, is removed by the belt conveyor 36 into the garbage bin 34. All operations, except for the installation of the package of sleepers by the slingers and sending it from the conveyor 7 by pressing the corresponding button, as well as cleaning the removable bins 33 and 34, on in section 1, the sleepers are laid out automatically.

At section 2 of the dismantling of the elements of the superstructure of the track, the following works are carried out.

1. Layout of sleepers along a diagram on a conveyor with diagram 10 (on conveyor 10, there is a set of sleepers per link - 46 or 50 sleepers simultaneously with moving to a step of the diagram), which is designed for individual reception of sleepers and moving them to a step of the diagram to form a set of sleepers per link ...

2. Transferring the fasteners of the ZhBR or W30 modifications to the mounting position by articulated robotic manipulators 22 or dismantling the elements of the ARS-type fasteners (monoregulators, corners and terminals) and placing them on the platforms of the diagram conveyor 10. The choice of dismantling or transferring to the mounting position is carried out depending on on the type of rail fastening with which the sleepers are equipped. At the same time, four articulated robotic manipulators of the same type were used for dismantling, which makes it possible to dismantle different types of fastening elements.

When working with modifications of ZhBR and W30 fasteners, the screws are pre-unscrewed with 37 screwdrivers for the further possibility of bringing the terminals into the mounting position by the robots.

When working with fastening of the APC type, the monoregulators are dismantled and, together with the corners and fastening terminals, are removed by robots onto the conveyor platforms 11, which are matrices for laying in their grooves the fastening elements of the APC type. In this case, the platforms with the APC fastening elements move from the section 2 for dismantling the fastening elements to the section 4 for mounting the fastening elements along their separate conveyor 11, which is located next to the left and right of the conveyor 10, on which the fastening elements are removed from the sleepers by robots. Thus, with the above direction, the platforms on the conveyor 11 move with filled elements of fasteners, and in the opposite direction - empty ones.

When working with a fastener of the PFK-350 type, only the mechanism for bringing the staples to the mounting position is involved in the work.

3. Removing from the diagram conveyor 10 a set of sleepers laid out along the diagram and transferring them by the trolley 25, as well as transferring the elements of fasteners of the APC type from the conveyor 11 to the assembly conveyor 12. The trolley includes a roller conveyor with a drive for moving the platform; a platform driven by a flexible traction element associated with the drive; support beams that transfer loads to the foundation of the complex. The trolley works as follows. After laying out the set of sleepers on the conveyor with diagram 10, the hydraulic cylinders raise the trolley 25 above the level of the conveyor belt 10, removing the set of sleepers. Upon completion of the lifting, the movement drive is switched on, and the trolley 25 with a set of sleepers moves to the area of the rail installer 13 to the position of the assembly conveyor 12, where it stops. In the raised position of the bogie, the rails are installed by the rail installer 13 from the roller tables 32 onto the link being assembled. Installing the rails on the sleepers when the position is raised above the assembly conveyor belts allows the conveyor 12 to move the previously assembled link to the position of its cleaning by gantry cranes 14. After installing the rails, the cart 25 is lowered to its lowest position and returns to its original position in the conveyor zone 10.

In section 3, the installation of rails was carried out the following operations:

- installation of rails by a rail installer 13 on sleepers;

- measurement and control of the parameters of the assembled link with equipment 24 and delivery of the link for its shipment by cranes 14.

The rail installer consists of a frame on which the drive for moving the carriages is located. The carriages are equipped with winches for vertical movement of the grippers connected to the carriages by rods. The grippers are controlled by actuators.

Equipment for automatic output control of links is a set of technical devices for measuring:

- track width along the length of the link and notification by signals about violation of assembly tolerances along the track width;

- the race of the link rails;

- the distance between the axles of the sleepers and notification by signals about the violation of the distance between the axles of the sleepers of the link;

- electrical resistance and air temperature and notification by signals about violation of tolerances for resistance values.

After installing the rails in section 3, the assembled link moves along the conveyor 10 to the position of section 4 for assembling elements of the superstructure of the track, where the articulated robotic manipulators 23 set the fasteners to the working (assembly) position. After completing this operation, the assembled link moves along the conveyor 12 outside the workshop to the work area of the gantry cranes 14.

Section 4 for mounting the fastening elements is similar in design to section 2 for dismantling. The difference is the reverse sequence of operations for assembling fasteners.

Example 1

The productivity of the complex is 125 linear meters. m / hour;

Time for processing one sleeper - 10-12 seconds (depending on the diagram of the sleepers);

Time for processing a link of 50 sleepers - 8-12 minutes (depending on the diagram of the sleepers);

The number of service personnel is in total - 22 people;

Collected links parameters:

- track - 1520 mm;

- the length of the links - 25 m;

- rails, type - Р65;

- sleepers, type - ShZ-D, ShS-ARS, Sh5-DF, ShP-350;

- fasteners, type - modifications of ZhBR, ARS, W30, PFK-350;

The number of packages of sleepers equipped with fasteners on the chain conveyor - 14 pcs .;

Number of rows in a package - 4 pcs.;

Number of sleepers in a row - 8 pcs.;

Distance between sleepers (sleepers diagram) - 500 mm or 543.5 mm;

The total number of sleepers on the chain conveyor is 448 pcs.

Example 2

Technical characteristics of the equipment of section 1 for the layout of sleepers:

- productivity - 250 sleepers / hour;

- the number of intermediate conveyors - 17 units;

- the total number of sleepers processed on the site - 448 pcs .;

- conveyor chains: traction chains, type of drive chains, speed of movement of conveyor chains - 0.12 m / s;

Technical characteristics of equipment of section 2 for dismantling of track superstructure elements:

- translational speed of movement of the diagram conveyor chains - 0.2, m / s;

- translational speed of movement of assembly conveyor chains - 0.2 m / s;

- trolley carrying capacity - 20 t;

- trolley travel speed - 0.15 m / s;

Trolley lifting hydraulic cylinder:

- quantity - 32 pcs .;

- piston diameter - 100 mm;

- stem diameter - 70 mm;

- stroke - 100 mm.

Articulated robot:

- model - Articulated Robot (for example, Kawasaki RS007L);

- degree of mobility - 6;

- drive - electric;

- capture - pneumatic;

- maximum payload - 7 kg.

- wrist type - classic;

- horizontal outreach: 800-1300 mm;

- vertical reach: 1300-1800 mm;

- repeatability: ± 0.03 mm;

- maximum reach: 800-1300 mm;

- range of motion: arm rotation: ± 180 °;

outstretched arm: ± 110-150 °;

hand up and down: ± 130-170 °;

- manipulator weight -36 kg.

Technical characteristics of the rail installer of the equipment of section 3 of the installation of rails:

- carrying capacity - 4 tons;

- lifting height - 6 m;

- lifting speed - 12 m / min.

Technical characteristics of the rail roller table of the equipment of section 5 of the preparation of rails:

- installed power of electric motors - 4 kW;

- rail travel speed (high) - 0.3 m / s;

- rail travel speed (low) - 0.06 m / s.

Gear motor:

- power - 0.25 kW;

- the number of revolutions - 30 rpm.

Thus, the claimed complex makes it possible to efficiently and quickly assemble the RSHR links with the sleepers equipped with fasteners.

Claims (15)

1. An automated complex for assembling a rail-and-sleep lattice of a railway track on sleepers, pre-equipped with elements of rail fasteners, characterized by the fact that it contains a series-installed crane for installing sleepers, a sleeper feed conveyor with a sleepers laying device located on it, a diagram conveyor, an assembly conveyor with an assembly above it a rail installer for installing rails on the link to be assembled and a crane for unloading the links of the rail and sleepers, and also contains at least one device for dismantling or transferring to the mounting position of the rail fastening elements on the sleepers, previously completed with them, when the sleepers are on the conveyor diagrammatically, and at least at least one device for mounting elements of rail fasteners on sleepers, when they are on the assembly conveyor, located behind the rail installer, while at least one device for dismantling or transferring the rail elements to the mounting position is fastened and / or at least one device for mounting rail fastening elements is made in the form of an articulated robotic manipulator having a multi-position gripper for acting on the rail fastening elements during their dismantling or transfer to the mounting position and / or mounting. 2. The complex according to claim 1, characterized by the fact that it contains a sleeper packs spreader into rows, which is located in front of the sleepers spreader. 3. The complex according to claim 2, characterized in that it contains a device for leveling the sleepers at the ends and a device for laying the sleepers, which ensures the receipt of the sleepers from the device for laying out the sleepers and laying them on a diagram conveyor. 4. The complex according to claim 1, characterized in that the diagram conveyor is configured to move the sleepers to a predetermined step of the diagram. 5. The complex according to claim 1, characterized in that it contains equipment for automatic measurement and control of at least one of the following parameters of the links of the rail and sleepers: - track width along the link length; - the race of the link rails; - the distance between the axles of the sleepers; - electrical resistance and air temperature. 6. The complex according to claim 1, characterized in that it contains a device for cleaning wooden gaskets and a device for cleaning the rows of sleepers from debris and snow installed in series on the conveyor for feeding the packages of sleepers. 7. The complex according to claim 1, characterized in that the conveyor for supplying the sleepers packages, the diagram conveyor and the assembly conveyor are made of chain. 8. The complex according to claim 1, characterized in that it contains a transporting device made in the form of a trolley for transferring the sleepers laid out along the diagram from the diagram conveyor to the assembly conveyor. 9. The complex according to claim 1, characterized in that it contains equipment for preliminary processing of rails and roller tables for moving rails from the warehouse to equipment for their preliminary processing. 10. The complex according to claim 9, characterized in that cleaning and / or rail-cutting and / or rail-drilling machines and / or machines for chamfering in holes are used as equipment for pre-processing of rails. 11. The complex according to claim 1, characterized in that the rail installer contains sensors for determining the location of the rails.

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