WO2019128014A1 - 一种无缝线路钢轨焊接修复车及修复方法 - Google Patents

一种无缝线路钢轨焊接修复车及修复方法 Download PDF

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Publication number
WO2019128014A1
WO2019128014A1 PCT/CN2018/084990 CN2018084990W WO2019128014A1 WO 2019128014 A1 WO2019128014 A1 WO 2019128014A1 CN 2018084990 W CN2018084990 W CN 2018084990W WO 2019128014 A1 WO2019128014 A1 WO 2019128014A1
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WO
WIPO (PCT)
Prior art keywords
rail
welding
main frame
joint
new
Prior art date
Application number
PCT/CN2018/084990
Other languages
English (en)
French (fr)
Inventor
陶小虎
张宝明
方健康
陈钦云
孙俊鑫
Original Assignee
中国铁建高新装备股份有限公司
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Application filed by 中国铁建高新装备股份有限公司 filed Critical 中国铁建高新装备股份有限公司
Publication of WO2019128014A1 publication Critical patent/WO2019128014A1/zh

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    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00—Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02—Working rail or other metal track components on the spot
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00—Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02—Working rail or other metal track components on the spot
    • E01B31/04—Sectioning or slitting, e.g. by sawing, shearing, flame-cutting
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00—Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02—Working rail or other metal track components on the spot
    • E01B31/12—Removing metal from rails, rail joints, or baseplates, e.g. for deburring welds, reconditioning worn rails
    • E01B31/17—Removing metal from rails, rail joints, or baseplates, e.g. for deburring welds, reconditioning worn rails by grinding
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00—Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02—Working rail or other metal track components on the spot
    • E01B31/18—Reconditioning or repairing worn or damaged parts on the spot, e.g. applying inlays, building-up rails by welding; Heating or cooling of parts on the spot, e.g. for reducing joint gaps, for hardening rails

Definitions

  • the invention relates to a seamless line rail welding repairing vehicle, belonging to the technical field of railway machinery design and manufacturing.
  • the severely injured section can be sawed.
  • the method of inserting the new rail section can complete the repair of the line.
  • the length of the new line inserted into the new line is generally not less than 6m, and the length of the new rail inserted into the high-speed railway is generally not less than 20m.
  • aluminum hot welding is mainly used to connect new rails into the line, but aluminum heat welding is difficult to ensure the quality of the joints, thus bringing certain safety hazards to the lines.
  • Rail welding is divided into on-site welding and base welding.
  • base welding uses fixed flash welding. Because the equipment of the base flash welder is huge, the single equipment that needs to be disassembled after the welding is completed is processed, the required space is large, the operators are many, the work efficiency is low, and the fixed flash welder cannot perform the transition, which greatly increases the number of Transportation is difficult.
  • the 3.2.1 fixed flash welding equipment on the first page of the "Trail Industry Standards of the People's Republic of China" TB/T1632.2-2005 requires that the fixed flash welding line should have a pre-weld rail straightening machine, sawing rail equipment, Rail end descaling equipment, rail flash butt welding equipment, post-weld rail straightening machine, rail head weld refiner and welded joint heat treatment device.
  • the equipment occupies a large area and there are many operators in use.
  • the straightening measuring device before welding is separated from the flash butt welding device. When used, it is easy to produce wrong variables, which directly affect the welding quality. 3. Due to the frequent construction of several passenger dedicated lines, there are multiple construction surfaces in the construction project, and the use of the base welding equipment is not convenient.
  • the utility model patent of the application No. 200620019354.1 discloses a mobile welding rail vehicle comprising a frame composed of front and rear horizontal frames and intermediate arch beams connecting them, a bogie arranged under the frame, and a hydraulic pressure
  • the jack and the rail lifter, as well as the cab and the power room arranged on the frame, are characterized in that a flash contact welding machine with a hanger is arranged on the frame below the arch beam.
  • the space under the frame arch beam can be fully utilized to facilitate the rail welding operation, and the center of gravity can be moved below the frame arch beam to increase the stability of the whole vehicle, and at the same time, the whole vehicle has a compact structure, convenient operation, flexibility, and safe operation; It also solves the problem of difficult transportation of supporting equipment.
  • the joint which is far from the driver's cab is a 1# joint, and the joint which is closer to the driver's cab is a 2# joint; the direction in which the parallel rail extends is a longitudinal direction, and the direction parallel to the sleeper is a transverse direction.
  • An aspect of the invention provides a seamless line rail welding repairing vehicle, comprising a main frame, wherein a cab is arranged on the main frame, and a working workshop covering the upper part of the main frame is arranged behind the driver's cab, and the main frame is two
  • the end includes a coupler
  • the lower part of the main frame includes a running part, an air compressor, a water tank, a hydraulic pump station and a tool box, and a hydraulic leg in a front-to-back manner
  • the main frame is loaded with a new rail
  • the working frame is in the working workshop
  • a power pack, a diesel tank, an end face processor, a saw rail machine, a gas supply room, a small machine tool, a welding head refining machine, a rail adjusting device, a welding rail machine are arranged in order from the front to the rear, and the working workshop also includes a telescopic beam.
  • One end of the telescopic beam is connected to the front door frame, and the lower part of the telescopic beam includes a crane I and a crane II.
  • the telescopic beam is supported by the support beam of the main frame through the roller to ensure that the working frame and the supporting beam slide relative to each other when the main frame is in operation, forming a A work shop that completely covers the severely wound area of the rail, the support beam being fixed to the main frame.
  • the support beam is connected to the telescopic beam by an upper roller, a middle roller and a lower roller.
  • the support beam is arranged symmetrically about the center of the telescopic beam, and the upper roller, the middle roller and the lower roller are respectively fitted in the sliding rail of the telescopic beam in a clearance fit manner, thereby The telescopic beam slides over the support beam.
  • the support beam includes a pillar in a vertical direction and a lateral support connected to the pillar, the pillar and the lateral support being symmetrically arranged with respect to the telescopic beam, the lateral support
  • the end portion includes the middle roller, the central axis of the middle roller is vertically vertical, so that the telescopic beam slides laterally relative to the support beam under the driving of the middle roller; the upper roller and the lower roller The central axis is laterally disposed to facilitate longitudinal sliding of the telescopic beam with the upper and lower rollers.
  • the front gantry includes a support device that is lowered and supported on the sleeper and the track bed during operation so that the work shop is relatively smoothly fixed to the track bed.
  • a hydraulic leg is provided at a rear lower portion of the main frame.
  • the work workshop comprises a front side wall, a rear side wall, a left side wall, a right side wall and a top surface, thereby forming a relatively closed space, and the telescopic beam is located in the working workshop. Below the top.
  • the front side wall of the work shop is movably connected to the right side wall or the left side wall so that the work shop slides out.
  • the present invention Compared with the prior art, the present invention has the following advantages and effects: the present invention can slide the telescopic beam of the working workshop backward on the support beam fixed on the main frame after the whole vehicle reaches the serious injury zone of the rail, thereby The work shop running on the main frame slides out to form a separate operation workshop that completely covers the seriously injured area of the rail.
  • the work shop saws the seriously injured rail section by the small equipment carried by itself, and the loading on the main frame is not more than
  • the new 20m rail is exchanged, then aligned, and the new rail is welded to the existing line by the welding machine to complete the welding repair of the seamless rail.
  • the invention can solve the problem of hoisting and replacement of the steel rail of ⁇ 20m, and can integrate the working functions such as pre-welding treatment (including saw rail, rail change, end face treatment), rail auxiliary alignment device, post-weld treatment (finishing, flaw detection, etc.) device.
  • pre-welding treatment including saw rail, rail change, end face treatment
  • rail auxiliary alignment device including rail auxiliary alignment device
  • post-weld treatment finishing, flaw detection, etc.
  • the working device and the staff are placed in the relatively closed space of the working workshop, which can reduce the interference of external factors on the welding quality and the noise of the working noise, and at the same time compared with the existing numerical control type pneumatic welding rail car. Or flash welding rail car, the degree of automation, work efficiency have improved.
  • the seamless line rail welding repairing vehicle provided by the invention is equipped with a small working tool such as a saw rail machine, a rail end face processing machine and a welding head refining machine, and can complete the sawing of the seriously injured rail, the new rail end face processing and the welding head shape fine.
  • the rectification operation is also equipped with a welding rail machine and a rail adjusting device, which can complete the connection of the new rail and the existing line.
  • the invention provides a complete set of equipment for repairing seamless track rails by using gas pressure welding or flash welding method, which not only reduces the labor intensity on site, but also can complete the connection of the new rail and the existing line with high efficiency and quality.
  • Another aspect of the present invention also provides a seamless line rail welding repairing method comprising:
  • the working workshop slides out of the main frame, and the front door frame connected to the front end of the working workshop protrudes from the supporting device, descends and supports on the sleeper and the track bed, and stabilizes the working workshop.
  • the ground is fixed on the track bed, and the main frame is driven away from the work shop under the power of the running part, until the distance along the line direction below the work shop satisfies the requirement of replacing the seriously injured steel rail segment;
  • the rail welding machine is sent to the 1# joint by the crane II, and the rail adjusting device holds the new rail and the existing rail for attitude adjustment. After the rail is aligned, the rail press holds the rail to be welded. Finish the welding of the 1# joint.
  • the crane II transports the welding machine to the 2# joint, and the rail adjusting device holds the new rail and the existing rail for attitude adjustment.
  • the rail press is to be welded. Rails (new rails and adjacent rails to be welded), complete welding of 2# joints;
  • the rail adjusting device and the welding rail machine are all higher than the upper surface of the main frame, and the main frame runs in the direction of the 1# joint until the receiving position of the working workshop is satisfied;
  • steps a, b, c, d, e, f, g, h are performed in sequence.
  • steps a, b, c, d, e, g, h are performed in sequence.
  • the seamless track rail welding repairing vehicle of the first aspect of the invention is employed.
  • FIG. 1 is a schematic view of a complete vehicle layout of a preferred embodiment of the seamless track rail welding repairing vehicle of the present invention (for convenience of description, the side wall portion of the working workshop 25 is hidden);
  • FIG. 2 is a schematic view of the vehicle receiving state of the embodiment shown in FIG. 1;
  • FIG 3 is a schematic view of the welding of the 1# joint of the embodiment shown in Figure 1 (for convenience of description, the side wall portion of the work shop 25 is hidden);
  • Figure 4 is an enlarged view of the welding of the 1# joint of the embodiment shown in Figure 1 (for convenience of description, the side wall portion of the work shop 25 is hidden);
  • FIG 5 is a schematic view of the welding of the 2# joint of the embodiment shown in Figure 1 (for convenience of description, the side wall portion of the work shop 25 is hidden);
  • Figure 6 is an enlarged view of the welding of the 2# joint of the embodiment shown in Figure 1 (for convenience of description, the side wall portion of the work shop 25 is hidden);
  • Figure 7 is a schematic view showing the connection of the roller, the middle roller and the lower roller on the embodiment shown in Figure 1;
  • Figure 8 is a schematic view of the upper, middle and lower rollers of the embodiment shown in Figure 1;
  • Embodiment 1.1 A seamless line rail welding repairing vehicle, comprising a main frame 2, the main frame 2 is provided with a cab 3, and a cab covering the upper part of the main frame 2 is arranged behind the cab 3 25, the main frame 2 includes a coupler 1 at both ends, in the lower part of the main frame 2 from the front to the rear including a running portion 4, an air compressor 12, a water tank 13, a hydraulic pump station 14 and a tool box, and a hydraulic leg 22;
  • the main frame 2 is loaded with a new rail 10, and the power pack 5, the diesel tank 6, the end face processing machine 8, the saw rail machine 9, the gas supply room I 11 and the gas supply room are arranged in the work shop 25 from front to back.
  • the work shop 25 further includes a telescopic beam 23, the telescopic beam 23 is connected at one end to the front door frame 24, and the lower portion of the telescopic beam 23 Including the crane I 7 and the crane II 19, the telescopic beam 23 is supported on the support beam 20 of the main frame 2 by rollers, and when the main frame 2 is in operation, the work shop 25 and the support beam 20 slide relative to each other, forming a completely covered rail serious injury. In the work shop of the area, the support beam 20 is fixed to the main frame 2.
  • the upper roller 201, the middle roller 202, and the lower roller 203 are connected to the telescopic beam 23.
  • the support beam 20 is arranged symmetrically about the center of the telescopic beam 23, and the upper roller 201, the middle roller 202 and the lower roller 203 are respectively fitted in the sliding rail of the telescopic beam 23 in a clearance fit manner, thereby The telescopic beam 23 slides on the support beam 20.
  • the support beam 20 includes a pillar in a vertical direction and a lateral support connected to the pillar, the pillar and the lateral support being symmetrically arranged with respect to the telescopic beam, the lateral support end including a middle roller 202, the middle roller 202
  • the central axis is vertically vertical so that the telescopic beam 23 slides laterally relative to the support beam 20 under the driving of the middle roller 202; the central axes of the upper roller 201 and the lower roller 203 are laterally disposed to facilitate the telescopic beam 23 is slid in the longitudinal direction by the upper roller 201 and the lower roller 203.
  • the front door frame 24 includes a supporting device 26 which is lowered and supported on the sleeper and the track bed during operation so that the work shop 25 is relatively smoothly fixed to the track bed, and the hydraulic leg 22 is disposed at the lower rear portion of the main frame 2.
  • the work workshop 25 includes a front side wall, a rear side wall, a left side wall, a right side wall and a top surface to form a relatively closed space, the telescopic beam 23 is located below the top surface of the work shop 25;
  • the front side wall is movably connected to the right side wall or the left side wall so that the work shop slides out.
  • the present invention can be applied to the support beam 20 fixed on the main frame 2 after the entire vehicle reaches the severely injured rail area of the work shop 25 After sliding out, the work shop 25 running on the main frame 2 slides out to form a separate working workshop completely covering the seriously injured area of the rail.
  • the work shop 25 saws the seriously injured rail section by the small machine carried by itself, and will
  • the new rails loaded on the main frame 2 of no more than 20m are exchanged, and then aligned, and the new rails are welded into the existing lines by the welding rail machine to complete the welding repair of the seamless line rails.
  • the invention can solve the problem of hoisting and replacement of the steel rail of ⁇ 20m, and can integrate the working functions such as pre-welding treatment (including saw rail, rail change, end face treatment), rail auxiliary alignment device, post-weld treatment (finishing, flaw detection, etc.) device.
  • pre-welding treatment including saw rail, rail change, end face treatment
  • rail auxiliary alignment device including rail auxiliary alignment device
  • post-weld treatment finishing, flaw detection, etc.
  • Embodiment 2.1 A seamless line rail welding repair method:
  • the work shop 25 slides out of the main frame 2 along the roller on the supporting beam 20, and the supporting device 26 of the front gantry 24 connected at one end of the working workshop 25 is downward. Extending, then descending and supporting on the sleeper and the track bed, the work shop 25 is stably fixed on the track bed, and the main frame 2 is driven by the power of the running part 4 to run away from the work shop 25 until the work place 25
  • the distance along the line direction meets the requirements for replacing severely injured rail segments, for example 20m;
  • the saw rail machine 9 in the work workshop 25 is respectively lowered to cut the two ends of the severely injured rail section, and the seriously injured rail is removed, and then the end face treatment machine 8 at both ends respectively is used for the adjacent steel rails 27 and 2# at the joint #1.
  • the end surface of the adjacent steel rail 28 at the joint is polished to facilitate subsequent welding, and the new rail 10 is suspended by the crane I7 and the crane II19 and dropped into the bearing groove;
  • the rail press 21 and the rail adjusting device 18 are sent to the 1# joint by the crane II19, and the rail adjusting device 18 clamps the existing rails 27 of the new rail 10 and the 1# joint for attitude adjustment.
  • the welding machine 21 clamps the to-be-welded portion of the adjacent rail 27 at the new rail 10 and the 1# joint to complete the welding of the 1# joint;
  • the crane II19 transports the rail press 21 rail adjusting device 18 to the 2# joint, and the rail adjusting device 18 clamps the existing rails 28 at the new rail 10 and 2# joints for posture adjustment.
  • the rail press 21 clamps the portion to be welded of the existing rail 28 at the new rail 10 and 2# joints, and completes the welding of the 2# joint;
  • the main frame 2 can be jacked up by the hydraulic leg 22 to release the load on the adjacent rail 28 at the 2# joint to ensure the alignment of the rail.
  • the effect meets the welding requirements
  • the rail adjusting device 18 and the rail welding machine 21 are all received above the upper surface of the main frame 2, and the main frame 2 is operated in the direction of the 1# joint until the receiving position of the working workshop 25 is satisfied;
  • Steps a1, b1, c1, d1, e1, f1, g1, h1 are sequentially executed.
  • the end face of the new rail 10 is untreated, it is sanded before the step b1 by the cross-section processor 8 in the work shop 25 to facilitate subsequent welding operations.
  • Embodiment 2.2 A seamless line rail welding repairing method comprising:
  • the work shop 25 slides out of the main frame 2 along the roller on the supporting beam 20, and the sawing machine 9 in the working workshop 25 reaches the 1# joint.
  • the work shop 25 stops sliding, and the supporting device 26 of the front door frame 24 connected at one end of the working workshop 25 protrudes downward, then descends and supports on the sleeper and the track bed, and the work workshop 25 is stably fixed on the track bed;
  • the saw rail machine 9 in the work shop 25 is lowered to cut the severely injured rail section near the 1# joint position;
  • the support device 6 is stowed, and the work shop 25 is locked with the main frame 2, and then the running portion 4 below the main frame 2 is driven to cause the work shop 25 to continue moving forward with the main frame 2, to be tracked by the track machine 9
  • the running portion 4 stops traveling, and the supporting device 26 of the front gantry 24 connected at one end of the working workshop 25 projects downward, then descends and supports on the sleeper and the track bed, and the work workshop 25 is stably fixed.
  • the saw rail machine 9 in the work shop 25 is lowered to cut the severely injured rail section near the 2# joint position;
  • the driving running portion 4 is operated backward until the front door frame 24 is located behind the 1# joint, and the work shop 25 is slid out of the main frame 2 along the roller on the support beam 20, and the front door frame 24 connected at one end of the working workshop 25 is supported.
  • the device 26 is extended downward, then lowered and supported on the sleeper and the track bed, and the work shop 25 is stably fixed on the track bed;
  • the main frame 2 is driven away from the work shop 25 under the power of the running portion 4 until the distance in the line direction below the work shop 25 satisfies the requirement of replacing the severely injured rail segment;
  • the rail press 21 and the rail adjusting device 18 are sent to the 1# joint by the crane II19, and the rail adjusting device 18 clamps the existing rails 27 of the new rail 10 and the 1# joint for attitude adjustment.
  • the welding machine 21 clamps the to-be-welded portion of the adjacent rail 27 at the new rail 10 and the 1# joint to complete the welding of the 1# joint;
  • the crane II19 transports the rail press 21 rail adjusting device 18 to the 2# joint, and the rail adjusting device 18 clamps the existing rails 28 at the new rail 10 and 2# joints for posture adjustment.
  • the rail press 21 clamps the portion to be welded of the existing rail 28 at the new rail 10 and 2# joints, and completes the welding of the 2# joint;
  • the rail adjusting device 18 and the rail welding machine 21 are all collected above the upper surface of the main frame 2, and the main frame 2 is operated in the direction of the 1# joint until the receiving position of the working workshop 25 is satisfied;
  • Steps a2, b2, c2, d2, e2, f2, g2, h2, i2, j2, k2, l2, m2, and n2 are sequentially performed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Machines For Laying And Maintaining Railways (AREA)

Abstract

一种无缝线路钢轨焊接修复车，包括主车架(2)，该主车架(2)上设置司机室(3)，主车架(2)两端包括车钩(1)，在主车架(2)下部由前向后依次包括走行部(4)、空压机(12)、水箱(13)、液压泵站(14)及工具箱和液压支腿(22)；司机室(3)后方设置有覆盖于主车架(2)上部的工作车间(25)，主车架(2)装载新钢轨(10)，工作车间(25)内由前向后依次设置动力包(5)、柴油箱(6)、端面处理机(8)、锯轨机(9)、气体供应间I(11)和气体供应间II(15)、小型机具(16)、焊头精磨机(17)、钢轨调节装置(18)、焊轨机(21)。该无缝线路钢轨焊接修复车装能够完成重伤钢轨的锯除、新轨端面处理和焊头外形精整等作业，还装有焊轨机、钢轨调节装置，可以完成新轨与既有线路的联入。

Description

一种无缝线路钢轨焊接修复车及修复方法 技术领域
本发明涉及一种无缝线路钢轨焊接修复车，属于铁路机械设计与制造技术领域。
背景技术
铁路线路存在大量的重伤接头，采用锯除重伤段，插入新轨段的方法可以对线路完成修复，普通线路插入新轨长度一般不小于6m，高速铁路插入新轨长度一般不小于20m。目前主要采用铝热焊将新轨联入线路中，但是铝热焊难以保证接头的质量，从而给线路带来一定的安全隐患。
钢轨焊接分为现场焊接和基地焊接,目前国内基地焊接大都采用固定式闪光焊接方式。由于基地闪光焊机的设备庞大，焊接完成后还需要分解的单体设备进行处理，需要的场地大、操作人员多、工效低、同时固定式闪光焊机无法进行转场，这样就大大增加了运输困难。如《中华人民共和国铁道行业标准》TB/T1632.2-2005中正文第一页的3.2.1固定式闪光焊接设备要求固定式闪光焊接作业线应有焊前钢轨校直机、锯轨设备、轨端除锈设备、钢轨闪光对焊设备、焊后钢轨矫直机、轨头焊缝精磨机以及焊接接头热处理装置。但其仍存在以下不足之处:1、设备占地大、使用时操作人员较多。2、焊接前的校直测量装置与闪光对焊装置分离，使用时极易产生错变量，直接影响焊接质量。3、由于经常遇到多条客运专线建设相继进行，工程建设项目存在多个作业面同时施工，基地焊轨设备转场使用不便利。
申请号为200620019354.1的中国实用新型专利公开了一种移动式焊轨车，其包括由前、后水平车架以及连接它们的中间拱梁构成的车架,设置在车架下方的转向架、液压顶升器及钢轨提升器,以及设置在车架上的司机室和动力间,其特征在于拱梁下方的车架上设用带吊架的闪光接触焊接机。可充分利用车架拱梁下方的空间，既便于钢轨焊 接作业，也可将重心移至车架拱梁下方，增加整车稳定性，同时使整车结构紧凑，操作方便、灵活，运行安全；也解决了配套设备运输困难的问题。但是随着时代的发展，其已经不能够满足现在高速铁路钢轨修复的作业要求。
发明内容
本发明设定距离司机室较远的接头为1#接头，距离司机室较近的接头为2#接头；平行钢轨延伸的方向为纵向，平行于轨枕的方向为横向。
本发明一方面提供一种无缝线路钢轨焊接修复车，包括主车架，该主车架上设置司机室，该司机室后方设置有覆盖于主车架上部的工作车间，主车架两端包括车钩，在主车架下部由前向后依次包括走行部、空压机、水箱、液压泵站及工具箱，和液压支腿；所述主车架装载新钢轨，所述工作车间内由前向后依次设置动力包、柴油箱、端面处理机、锯轨机、气体供应间、小型机具、焊头精磨机、钢轨调节装置、焊轨机，所述工作车间还包括伸缩梁，该伸缩梁一端连接前门架，该伸缩梁下部包括吊车I和吊车II，伸缩梁通过滚轮支撑于主车架的支撑梁上，保证主车架运行时，工作车间与支撑梁相对滑动，形成一个完全覆盖钢轨重伤区的作业车间，所述支撑梁固装于所述主车架上。
优选的是，所述支撑梁上方通过上滚轮、中滚轮、下滚轮与所述伸缩梁连接。
更优选的是，所述支撑梁以伸缩梁为中心左右对称布置，所述上滚轮、中滚轮和所述下滚轮分别以间隙配合的方式嵌装在所述伸缩梁的滑轨内，从而使所述伸缩梁在所述支撑梁上滑动。
在上述任一方案中优选的是，所述支撑梁包括竖直方向的支柱和与该支柱连接的横向支撑，所述支柱与所述横向支撑关于所述伸缩梁轴对称布置，所述横向支撑末端包括所述中滚轮，该中滚轮的中心轴线竖直为竖直方向，以便所述伸缩梁在该中滚轮的带动下沿横向相对于所述支撑梁滑移；所述上滚轮和下滚轮的中心轴线为横向设置，便于所 述伸缩梁在所述上滚轮和下滚轮的带动下沿纵向滑移。
在上述任一方案中优选的是，所述前门架包括支撑装置，作业时，该支撑装置下降并支撑于轨枕及道床上，使得工作车间相对平稳地固定在道床上。
在上述任一方案中优选的是，所述主车架后方下部设置液压支腿。
在上述任一方案中优选的是，所述工作车间包括前侧墙、后侧墙、左侧墙、右侧墙及顶面，从而构成相对封闭的空间，所述伸缩梁位于所述工作车间的顶面下方。
在上述任一方案中优选的是，所述工作车间的前侧墙与所述右侧墙或左侧墙活动连接，以便所述工作车间滑出。
本发明与现有技术相比具有下列优点和效果：本发明可以在整车到达钢轨重伤区后，所述工作车间的伸缩梁在主车架上固装的支撑梁上向后滑出，从而以主车架运行的工作车间滑出的方式，形成一个完全覆盖钢轨重伤区域的独立作业车间，该工作车间通过自身携带的小型机具将重伤钢轨段锯除，将主车架上装载的不大于20m的新钢轨换入，然后对正，再采用焊轨机将新轨焊接联入既有线路，完成无缝线路钢轨的焊接修复。
本发明可解决≤20m钢轨的吊装、更换问题，可集成配备焊前处理(包含锯轨、换轨、端面处理)、钢轨辅助对位装置、焊后处理(精整、探伤等)等作业功能设备。作业时无须顶起整车，提高作业的安全性，且无需考虑作业完成后的落轮入轨问题，相对而言，效率较高。
本发明在运行及作业时，工作装置、工作人员均置于工作车间这个相对封闭的空间，可减少外界因素对焊接质量的干扰和作业噪音等污染，同时相对于现有数控式气压焊轨车或闪光焊轨车，自动化程度、作业效率均有提升。
本发明提供的无缝线路钢轨焊接修复车装有锯轨机、钢轨端面处理机、焊头精磨机等小型作业机具，可以完成重伤钢轨的锯除、新轨端面处理和焊头外形精整等作业，还 装有焊轨机、钢轨调节装置，可以完成新轨与既有线路的联入。
本发明提供一种采用气压焊或闪光焊方法进行修复无缝线路钢轨的整套设备，不仅可降低现场劳动强度，而且能够高效、保质的完成新轨与既有线路的连接。
本发明另一方面还提供一种一种无缝线路钢轨焊接修复方法：其包括：
a.无缝线路钢轨焊接修复车到达钢轨重伤区后，将工作车间滑出主车架，工作车间前端连接的前门架伸出支撑装置，下降并支撑于轨枕及道床上，将工作车间稳定地固定在道床上，主车架在走行部的动力驱动下向背离工作车间的方向运行，直至工作车间下方沿线路方向的距离满足更换重伤钢轨段要求；
b.采用随车携带的锯轨机将重伤钢轨段两端切开，并将重伤钢轨移出；
c.采用吊车将新钢轨吊下并落入承轨槽中。
d.新钢轨到位后，通过吊车II将焊轨机送至1#接头处，同时钢轨调节装置夹持新钢轨与既有线钢轨进行姿态调节，对正钢轨后，焊轨机夹持待焊钢轨完成1#接头的焊接。
e.1#接头焊接完成后，吊车II将焊轨机运送至2#接头处，同时钢轨调节装置夹持新钢轨与既有线钢轨进行姿态调节，对正钢轨后，焊轨机夹持待焊钢轨(新轨与既有线钢轨待焊部分)，完成2#接头的焊接；
f.焊接2#头时，通过液压支腿将主车架顶起从而释放走行部在既有线钢轨上的负荷，以保证钢轨对正的效果满足焊接要求；
g.2#接头焊接完成后，钢轨调节装置、焊轨机均收至高于主车架上表面，主车架向1#接头方向运行，直至满足工作车间的收车位置；
h.收回所有装置，整车运行离开修复区域，至此完成无缝线路钢轨重伤段的修复。
优选的是，依次执行步骤a、b、c、d、e、f、g、h。
优选的是，依次执行步骤a、b、c、d、e、g、h。
优选的是，采用本发明第一方面所述的无缝线路钢轨焊接修复车。
附图说明
图1为本发明所述无缝线路钢轨焊接修复车的一优选实施例之整车布局示意图(为方便描述，隐藏了工作车间25侧墙部分)；
图2为图1所示实施例之整车收车状态示意图；
图3为图1所示实施例之1#接头焊接示意图(为方便描述，隐藏了工作车间25侧墙部分)；
图4为图1所示实施例之1#接头焊接放大图(为方便描述，隐藏了工作车间25侧墙部分)；
图5为图1所示实施例之2#接头焊接示意图(为方便描述，隐藏了工作车间25侧墙部分)；
图6为图1所示实施例之2#接头焊接放大图(为方便描述，隐藏了工作车间25侧墙部分)；
图7为图1所示实施例之上滚轮、中滚轮和下滚轮的连接示意图；
图8为图1所示实施例之上、中、下滚轮示意图；
图1-图8中的数字标记的含义如下：
1车钩 2主车架 3司机室 4走行部 5动力包
6柴油箱 7吊车I 8端面处理机 9锯轨机 10新钢轨
11气体供应间I 12空压机 13水箱 14液压泵站 15气体供应间II
16小型机具 17焊头精磨机18钢轨调节装置 19吊车II 20支撑梁
21焊轨机 22液压支腿 23伸缩梁 24前门架 25工作车 间
26支撑装置 27 1#接头处既有线钢轨 28 2#接头处既有线钢轨
201上滚轮 202中滚轮 203下滚轮。
具体实施方式
下面结合附图对本发明做进一步描述。
实施例1.1:一种无缝线路钢轨焊接修复车，其包括主车架2，该主车架2上设置司机室3，该司机室3后方设置有覆盖于主车架2上部的工作车间25，主车架2两端包括车钩1，在主车架2下部由前向后依次包括走行部4、空压机12、水箱13、液压泵站14及工具箱，和液压支腿22；所述主车架2装载新钢轨10，所述工作车间25内由前向后依次设置动力包5、柴油箱6、端面处理机8、锯轨机9、气体供应间I 11和气体供应间II 15、小型机具16、焊头精磨机17、钢轨调节装置18、焊轨机21，所述工作车间25还包括伸缩梁23，该伸缩梁23一端连接前门架24，该伸缩梁23下部包括吊车I 7和吊车II 19，伸缩梁23通过滚轮支撑于主车架2的支撑梁20上，保证主车架2运行时，工作车间25与支撑梁20相对滑动，形成一个完全覆盖钢轨重伤区的作业车间，支撑梁20固装于所述主车架2上。
支撑梁20上方通过上滚轮201、中滚轮202、下滚轮203与所述伸缩梁23连接。
支撑梁20以伸缩梁23为中心左右对称布置，所述上滚轮201、中滚轮202和所述下滚轮203分别以间隙配合的方式嵌装在所述伸缩梁23的滑轨内，从而使所述伸缩梁23在所述支撑梁20上滑动。
支撑梁20包括竖直方向的支柱和与该支柱连接的横向支撑，所述支柱与所述横向支撑关于所述伸缩梁轴对称布置，所述横向支撑末端包括中滚轮202，该中滚轮202的中心轴线竖直为竖直方向，以便伸缩梁23在该中滚轮202的带动下沿横向相对于支撑 梁20滑移；所述上滚轮201和下滚轮203的中心轴线为横向设置，便于伸缩梁23在上滚轮201和下滚轮203的带动下沿纵向滑移。
前门架24包括支撑装置26，作业时，该支撑装置26下降并支撑于轨枕及道床上，使得工作车间25相对平稳地固定在道床上，主车架2后方下部设置液压支腿22。
工作车间25包括前侧墙、后侧墙、左侧墙、右侧墙及顶面，从而构成相对封闭的空间，所述伸缩梁23位于所述工作车间25的顶面下方；工作车间25的前侧墙与所述右侧墙或左侧墙活动连接，以便所述工作车间滑出。
上述实施例与现有技术相比具有下列优点和效果：本发明可以在整车到达钢轨重伤区后，所述工作车间25的伸缩梁23在主车架2上固装的支撑梁20上向后滑出，从而以主车架2运行的工作车间25滑出的方式，形成一个完全覆盖钢轨重伤区域的独立作业车间，该工作车间25通过自身携带的小型机具将重伤钢轨段锯除，将主车架2上装载的不大于20m的新钢轨换入，然后对正，再采用焊轨机将新轨焊接联入既有线路，完成无缝线路钢轨的焊接修复。
本发明可解决≤20m钢轨的吊装、更换问题，可集成配备焊前处理(包含锯轨、换轨、端面处理)、钢轨辅助对位装置、焊后处理(精整、探伤等)等作业功能设备。作业时无须顶起整车，提高作业的安全性，且无需考虑作业完成后的落轮入轨问题，相对而言，效率较高。
实施例2.1：一种无缝线路钢轨焊接修复方法：
a1.无缝线路钢轨焊接修复车到达钢轨重伤区后，将工作车间25沿着支撑梁20上的滚轮滑出主车架2，工作车间25一端连接的前门架24的支撑装置26向下伸出，然后下降并支撑于轨枕及道床上，将工作车间25稳定地固定在道床上，主车架2在走行部4 的动力驱动下向背离工作车间25的方向运行，直至工作车间25下方沿线路方向的距离满足更换重伤钢轨段要求，例如20m；
b1.工作车间25内的锯轨机9分别下放将重伤钢轨段两端切开，并将重伤钢轨移出，然后用两端的端面处理机8分别对1#接头处的既有线钢轨27和2#接头处的既有线钢轨28的端面进行打磨处理，方便后续焊接，再采用吊车I7、吊车II19将新钢轨10吊下并落入承轨槽中；
c1.新钢轨10到位后，通过吊车II19将焊轨机21及钢轨调节装置18送至1#接头处，钢轨调节装置18夹持新钢轨10与1#接头处的既有线钢轨27进行姿态调节，对正钢轨后，焊轨机21夹持新钢轨10与1#接头处的既有线钢轨27的待焊部分，完成1#接头的焊接；
d1.1#接头焊接完成后，吊车II19将焊轨机21钢轨调节装置18运送至2#接头处，钢轨调节装置18夹持新钢轨10与2#接头处的既有线钢轨28进行姿态调节，对正钢轨后，焊轨机21夹持新钢轨10与2#接头处的既有线钢轨28的待焊部分，完成2#接头的焊接；
e1.焊接2#头时，根据实际工况需求，可通过液压支腿22将主车架2顶起从而释放走行部在2#接头处的既有线钢轨28上的负荷，以保证钢轨对正的效果满足焊接要求；
f1.用吊车II19将焊头精磨机17分别吊至1#接头和2#接头处并对1#接头和2#接头进行精磨；
g1.将钢轨调节装置18、焊轨机21均收至主车架2的上表面以上的位置，主车架2向1#接头方向运行，直至满足工作车间25的收车位置；
h1.收回所有作业装置，整车运行离开修复区域，至此完成无缝线路钢轨重伤段的修复。
依次执行步骤a1、b1、c1、d1、e1、f1、g1、h1。
优选的是，如果新钢轨10的端面未经处理，在步骤b1之前采用工作车间25内的断面处理机8打磨处理，便于后续焊接作业。
实施例2.2：一种无缝线路钢轨焊接修复方法，其包括：
a2.无缝线路钢轨焊接修复车到达钢轨重伤区后，将工作车间25沿着支撑梁20上的滚轮滑出主车架2，待工作车间25内的锯轨机9到达1#接头的切割位置时，工作车间25停止滑动，工作车间25一端连接的前门架24的支撑装置26向下伸出，然后下降并支撑于轨枕及道床上，将工作车间25稳定地固定在道床上；
b2.工作车间25内的锯轨机9下放将1#接头位置附近的重伤钢轨段切开；
c2.收起支撑装置6，并将工作车间25与主车架2锁定，然后驱动主车架2下方的走行部4使工作车间25随主车架2继续向前走行，待锯轨机9到达2#接头的切割位置时，走行部4停止走行，工作车间25一端连接的前门架24的支撑装置26向下伸出，然后下降并支撑于轨枕及道床上，将工作车间25稳定地固定在道床上；
d2.工作车间25内的锯轨机9下放将2#接头位置附近的重伤钢轨段切开；
e2.收起支撑装置6，并将工作车间25与主车架2再次锁定；
f2.驱动走行部4向后运行，直至前门架24位于1#接头后方，将工作车间25沿着支撑梁20上的滚轮滑出主车架2，工作车间25一端连接的前门架24的支撑装置26向下伸出，然后下降并支撑于轨枕及道床上，将工作车间25稳定地固定在道床上；
g2.主车架2在走行部4的动力驱动下向背离工作车间25的方向运行，直至工作车间25下方沿线路方向的距离满足更换重伤钢轨段要求；
h2.将锯开的钢轨移出，然后采用吊车I7、吊车II19将新钢轨10吊下并落入承轨 槽中。
i2.新钢轨10到位后，通过吊车II19将焊轨机21及钢轨调节装置18送至1#接头处，钢轨调节装置18夹持新钢轨10与1#接头处的既有线钢轨27进行姿态调节，对正钢轨后，焊轨机21夹持新钢轨10与1#接头处的既有线钢轨27的待焊部分，完成1#接头的焊接；
j2.1#接头焊接完成后，吊车II19将焊轨机21钢轨调节装置18运送至2#接头处，钢轨调节装置18夹持新钢轨10与2#接头处的既有线钢轨28进行姿态调节，对正钢轨后，焊轨机21夹持新钢轨10与2#接头处的既有线钢轨28的待焊部分，完成2#接头的焊接；
k2.焊接2#头时，通过液压支腿22将主车架2顶起从而释放走行部在2#接头处的既有线钢轨28上的负荷，以保证钢轨对正的效果满足焊接要求；
l2.用吊车II19将焊头精磨机17分别吊至1#接头和2#接头处并对1#接头和2#接头进行精磨；
m2.将钢轨调节装置18、焊轨机21均收至主车架2的上表面以上的位置，主车架2向1#接头方向运行，直至满足工作车间25的收车位置；
n2.收回所有作业装置，整车运行离开修复区域，至此完成无缝线路钢轨重伤段的修复。
依次执行步骤a2、b2、c2、d2、e2、f2、g2、h2、i2、j2、k2、l2、m2、n2。

Claims (10)

  1. 一种无缝线路钢轨焊接修复车，其包括主车架(2)，该主车架(2)上设置司机室(3)，主车架(2)两端包括车钩(1)，在主车架(2)下部由前向后依次包括走行部(4)、空压机(12)、水箱(13)、液压泵站(14)及工具箱，和液压支腿(22)；其特征在于：该司机室(3)后方设置有覆盖于主车架(2)上部的工作车间(25)，主车架(2)装载新钢轨(10)，工作车间(25)内由前向后依次设置动力包(5)、柴油箱(6)、端面处理机(8)、锯轨机(9)、气体供应间I(11)和气体供应间II(15)、小型机具(16)、焊头精磨机(17)、钢轨调节装置(18)、焊轨机(21)，工作车间(25)还包括伸缩梁(23)，该伸缩梁(23)一端连接前门架(24)，该伸缩梁(23)下部包括吊车I(7)和吊车II(19)，伸缩梁(23)通过滚轮支撑于主车架(2)的支撑梁(20)上，保证主车架(2)运行时，工作车间(25)与支撑梁(20)相对滑动，形成一个完全覆盖钢轨重伤区的作业车间，支撑梁(20)固装于主车架(2)上。
  2. 如权利要求1所述的无缝线路钢轨焊接修复车，其特征在于：支撑梁(20)上方通过上滚轮(201)、中滚轮(202)、下滚轮(203)与所述伸缩梁(23)连接。
  3. 如权利要求1所述的无缝线路钢轨焊接修复车，其特征在于：支撑梁(20)以伸缩梁(23)为中心左右对称布置。
  4. 如权利要求1所述的无缝线路钢轨焊接修复车，其特征在于：所述上滚轮(201)、中滚轮(202)和所述下滚轮(203)分别以间隙配合的方式嵌装在所述伸缩梁(23)的滑轨内，从而使所述伸缩梁(23)在所述支撑梁(20)上滑动。
  5. 如权利要求1所述的无缝线路钢轨焊接修复车，其特征在于：支撑梁(20)包括竖直方向的支柱和与该支柱连接的横向支撑，所述支柱与所述横向支撑关于所述伸缩梁轴对称布置，所述横向支撑末端包括中滚轮(202)，该中滚轮(202)的中心轴线竖直为竖直方向上滚轮(201)和下滚轮(203)的中心轴线为横向设置。
  6. 如权利要求1所述的无缝线路钢轨焊接修复车，其特征在于：前门架(24)包括支撑装 置(26)，作业时，该支撑装置(26)下降并支撑于轨枕及道床上，使得工作车间(25)相对平稳地固定在道床上。
  7. 如权利要求1所述的无缝线路钢轨焊接修复车，其特征在于：主车架(2)后方下部设置液压支腿(22)。
  8. 如权利要求1所述的无缝线路钢轨焊接修复车，其特征在于：工作车间(25)包括前侧墙、后侧墙、左侧墙、右侧墙及顶面，从而构成相对封闭的空间，所述伸缩梁(23)位于所述工作车间(25)的顶面下方；工作车间(25)的前侧墙与所述右侧墙或左侧墙活动连接。
  9. 一种无缝线路钢轨焊接修复方法，其特征在于包括以下步骤：
    a1.无缝线路钢轨焊接修复车到达钢轨重伤区后，将工作车间(25)沿着支撑梁(20)上的滚轮滑出主车架(2)，工作车间(25)一端连接的前门架(24)的支撑装置(26)向下伸出，然后下降并支撑于轨枕及道床上，将工作车间(25)稳定地固定在道床上，主车架(2)在走行部(4)的动力驱动下向背离工作车间(25)的方向运行，直至工作车间(25)下方沿线路方向的距离满足更换重伤钢轨段要求，例如20m；
    b1.工作车间(25)内的锯轨机(9)分别下放将重伤钢轨段两端切开，并将重伤钢轨移出，然后用两端的端面处理机(8)分别对1#接头处的既有线钢轨(27)和2#接头处的既有线钢轨(28)的端面进行打磨处理，方便后续焊接，再采用吊车I(7)、吊车II(19)将新钢轨(10)吊下并落入承轨槽中；
    c1.新钢轨(10)到位后，通过吊车II(19)将焊轨机(21)及钢轨调节装置(18)送至1#接头处，钢轨调节装置(18)夹持新钢轨(10)与1#接头处的既有线钢轨(27)进行姿态调节，对正钢轨后，焊轨机(21)夹持新钢轨(10)与1#接头处的既有线钢轨(27)的待焊部分，完成1#接头的焊接；
    d1.1#接头焊接完成后，吊车II(19)将焊轨机(21)钢轨调节装置(18)运送至2#接头处， 钢轨调节装置(18)夹持新钢轨(10)与2#接头处的既有线钢轨(28)进行姿态调节，对正钢轨后，焊轨机(21)夹持新钢轨(10)与2#接头处的既有线钢轨(28)的待焊部分，完成2#接头的焊接；
    e1.焊接2#头时，根据实际工况需求，可通过液压支腿(22)将主车架2顶起从而释放走行部在2#接头处的既有线钢轨(28)上的负荷，以保证钢轨对正的效果满足焊接要求；
    f1.用吊车II(19)将焊头精磨机(17)分别吊至1#接头和2#接头处并对1#接头和2#接头进行精磨；
    g1.将钢轨调节装置(18)、焊轨机(21)均收至主车架(2)的上表面以上的位置，主车架(2)向1#接头方向运行，直至满足工作车间(25)的收车位置；
    h1.收回所有作业装置，整车运行离开修复区域，至此完成无缝线路钢轨重伤段的修复。
    依次执行步骤a1、b1、c1、d1、e1、f1、g1、h1。
  10. 如权利要求9所述的无缝线路钢轨焊接修复方法，其特征在于：在步骤b1之前采用工作车间(25)内的断面处理机(8)打磨处理新钢轨(10)。
PCT/CN2018/084990 2017-12-29 2018-04-28 一种无缝线路钢轨焊接修复车及修复方法 WO2019128014A1 (zh)

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