EP0460778B1 - Attachment for a railway rail base plate and method for obtaining a switch and a steel Y shaped sleeper - Google Patents

Abstract

An attachment for railway rail base plate on Y-shaped steel sleepers (12) and a method for producing a Y-shaped steel sleeper and a switch consisting of Y-shaped steel sleepers are proposed, in which an insulating plate (19) and a ribbed plate (3) situated on the latter are arranged on the upper flanges (22) of the double-T carriers which are welded together. The ribbed plate (3) is held resiliently by means of a bolt (27) which is surrounded with clearance by an insulating bush (31) adapted thereto and which is fixed to the upper flange of the T carrier by a bolt-welding technique. <IMAGE>

Description

The invention relates to a mounting for a track plate and a method for producing a switch and a Y-shaped steel sleeper for a railway according to the preambles of claims 1, 4 and 6.

Track plates are fastened, for example, as ribbed plates or sliding chairs for rail mounting on wooden sleepers (DE-C-35 26 653) or concrete sleepers with wood screws directly or in appropriate dowels.

CH-A-396960 shows the fastening of a track plate on a steel or concrete bridge with the interposition of an insulating plate. Eccentric insulating bushes are inserted into the holes in the track plate, which are intended to correct inaccuracies in the arrangement of the bolts for fastening the track plates or to allow the track width or the lines of the rails to be readjusted.

The insulating bushes, which are provided with an eccentric bore and are loosely inserted into the ribbed plate, are to allow precise positioning of the rails by being supported on the fastening bolts.
The type of attachment leads to partial destruction of the insulating plate in the area of the load Holes in the ribbed plate and to a bending load on the fastening bolt.

Welded-on ribs with rail guides in between are known for Y steel sleepers (DE-A-35 06 154). Y-steel sleeper switches with - but relatively expensive - electrically insulated, screwed track plate fastening (DE-A-37 08 752) have also been proposed. The use of Y-sleepers for switches is also known from DE-C-35 31 855 and DE-C-38 28 440.

Track plates for Y-steel sleepers are still used today as connectors for the upper chords of the adjacent double-T beams and welded to them (DE magazine "ETR Eisenbahntechnische Rundschau", issue 1-2, 1988, pp. 67-70 and DE-U -87 09 429.0). To prevent crevice corrosion between the track plates and the top chords and to prevent the gap from bending due to load, the track plates must be welded all around and from the underside of the sleeper. When manufacturing individual sleepers, these have to be turned. The production of a turnout from Y-steel sleepers with such track plates is even more difficult. After the position of the rail support points and thus the track plates has been marked, the track plates with the rails on them are first welded on one side and then the entire switch or the part of a switch that is ready to be installed must be turned to weld the track plates from the underside. Overhead welding is prohibited for reasons of space, visibility and security.

Another problem arises from the series production of the Y steel sleepers. Different rail operators want different reasons for their own safety standards and warehousing, e.g. B. electrically insulated rail fasteners and accordingly different track plates. As a result, only small lot sizes can be produced with certain track plates.

It is therefore an object of the invention to propose electrically insulating fastenings of track plates on Y-steel sleepers in ballast and asphalt bedding, which allow the use of different track plates, but are very inexpensive and large-scale production and the production of corresponding Y-steel sleepers and switches made of Y - enable steel sleepers. The disadvantages of the prior art should be avoided.

To solve the problem, it is assumed that a track plate provided with holes is attached to Y-shaped steel sleepers for a railroad consisting of double-T beams, comprising bushings which are fitted into the holes and bolts whose shafts with play through holes in the Sockets protrude and an insulating plate arranged between the track plate and the steel sleeper with passages for the screw bolts and the sockets, which correspond approximately to the size of the holes in the track plate (cf. DE-A-3708752), in which, according to the invention, the sockets are made of hard plastic existing insulating bushes are designed and in which the bolts consist of bolts which are attached to the double-T-beams from the top of the threshold by bolt welding at an exact distance from one another.

This attachment has several advantages.
Almost any track plates, ribbed plates or sliding chairs can be used, which only have to have predetermined hole distances for their attachment to the welding stud, so that series production is also possible for Y-steel sleepers, similar to the wooden sleepers.
Attempts are known to realize the rail fastening itself by means of welded-in screw bolts in steel trough sleepers (DE-C-494 119), however, additional strengthening of the local threshold areas was required and the welding was also carried out very laboriously from the underside of the sleepers.
Furthermore, it is known to fasten the rail base on screw bolts welded to a metal base on crane rails (DE-A-28 20 458), but specially processed metal bases or fastening elements are required for this purpose, which create space for the welding beads.
An optional specification, for example to use welded bolts for a resilient crane rail fastening, can be found in DE-C-21 07 374. The above-mentioned method of welding the bolts by hand does not solve the problem of series production; the problem of isolating from Rails addressed on Y steel sleepers. Punching or processing the double-T beams is not possible for structural and manufacturing reasons.

The use of stud welding at the previously determined fastening points also enables defined penetration conditions during welding through the standard use of the usual welding bead-forming ceramic rings and the resulting defined bead size. The method permits series production of the fastening according to the invention. Problems with welding spatter, as is common with manual welding, are excluded with the stud welding technology mentioned. In the case of a fastening according to the invention, the actual rail fastening no longer requires electrical insulation, so that commercially available, non-insulated or isolatable, fastening of rails on ribbed plates by means of hook screws and conventional K fastening or resilient fastening can be used.
In addition to the electrically insulating effect, the insulating plate, for example made of cellular plastic material, can also be assigned a resilient effect for the elastic fastening of the rib plate. This spring action is used in particular for asphalt or concrete bedding of the tracks, in which the elastic behavior of the track body is simulated by a depression characteristic of an insulating plate made of plastic, which is similar to ballast bedding. The ones to be specified Plastic thicknesses and material stiffness can be calculated exactly, as practical tests have shown.

Bushings that are made of hard plastic, e.g. B. are made of glass fiber reinforced polyamide insulating sleeves, remain true to shape with the occurring mechanical loads and temperatures. The definition of the bushing size makes it easy to insert the ribbed plate with the bushing and prevents the introduction of a bending moment on the screw shafts in the event of a transverse displacement of the track plate due to the rail load. In extensive tests, it was found that this transverse displacement in the fastening according to the invention can be limited to 0.1 to 0.3 mm even after several million load cycles. This allows a close tolerance of the bush geometry.

The welding point of the bolt on the threshold is provided with permanent corrosion protection, for example made of a bitumen material or a special epoxy resin mixture, which is set softly for the usual temperature load of rails from -40 ° C to + 80 ° C. This prevents corrosion media from attacking the weld. To apply the corrosion protection, the insulating plates are equipped according to the invention with large passages which, in accordance with the hole cross sections, can accommodate a defined mass of corrosion protection agent.

According to a development of the invention, the attachment of the z. B. designed as a ribbed plate or sliding chair track plate with a spring on the bolt between the insulating bush and nut. This feather serves several purposes. A desired sinking depth of the insulating plate under load can be defined in a defined manner by using a spring or made safer without loosening the screw connection. In addition, the tightening torque of the screw connection can be metered more sensitively.

In the rough operation of track construction technology, it makes sense to display the applied spring tension instead of or in addition to a defined torque for the screw connection. For this purpose, according to the invention, appropriate means, for. B. a plastic cap is provided, which indicate a certain travel, in which the cap rests on its base.

• Herstellen der Y-förmigen Stahlschwellen aus Doppel-T-Trägern, die an ihren Enden in definiertem Abstand zueinander verschweißt sind und jeweils an zwei Enden einen Schienenstützpunkt bilden, in der ihrer Weichenposition entsprechenden vorgegebenen Länge,
• Errechnung der Position der Schienenstützpunkte auf der Stahlschwelle relativ zur Weichenachse,
• Ermittlung der Lage der Befestigungspunkte von Rippenplatten relativ zum Schienenstützpunkt bzw. zu einer Referenzachse auf jedem Träger,
• Ansteuern der Befestigungspunkte mit einem Bolzenschweißgerät,
• Befestigung von Schraubenbolzen von der Schwellenoberseite her durch Bolzenschweißen auf den T-Trägern in den Befestigungspunkten und gegebenenfalls
• Montage der Spurplattern, Einbringen eines Korrosionsschutzmittels am Fuß des Schraubenbolzens und anschließende Montage der vorgefertigten Fahrwegbauteile auf den Schwellen eines der Transportlänge entsprechenden Abschnittes der Weiche, und ein

Verfahren zur Herstellung einer Y-förmigen Stahlschwelle mit einer Befestigung für eine Spurplatte der eingangs beschriebenen Art, welches durch folgende Verfahrensschritte gekennzeichnet ist:

• Herstellen der Y-förmigen Stahlschwellen aus Doppel-T-Trägern von denen je zwei mit ihren Enden einen gemeinsamen Schienenstützpunkt bilden durch Verschweißen der Untergurte und Obergurte benachbarter T-Träger, gegebenenfalls unter Einfügung von stabilen biegesteifen Abstandhaltern,
• Ermittlung der Lage der Befestigungspunkte einer Spurplatte relativ zur Außenkante der Stahlschwellen,
• Befestigung der Schraubenbolzen mittels Bolzenschweißung auf den zuvor ermittelten Befestigungspunkten und
• gegebenenfalls Montage der Spurplatten und Einbrigen eines Korrosionsschutzmittels rund um die Schweißstelle der Schraubenbolzen.

The object is further achieved according to the invention by a method for producing a switch of a railway from Y-shaped steel sleepers on which track plates for rail mounting are arranged, which is characterized by the following method steps:

• Manufacture of the Y-shaped steel sleepers from double-T beams, which are welded at their ends at a defined distance from one another and each form a rail support point at two ends, in the predetermined position corresponding to their switch position Length,
• Calculation of the position of the rail support points on the steel sleeper relative to the switch axis,
• Determining the position of the fastening points of ribbed plates relative to the rail base or to a reference axis on each support,
• Control of the fastening points with a stud welding device,
• Fastening bolts from the top of the sleeper by welding the bolts on the T-beams in the fastening points and if necessary
• Assembly of the track plates, introduction of an anti-corrosion agent at the foot of the bolt and subsequent assembly of the prefabricated track components on the sleepers of a section of the switch corresponding to the transport length, and a

Method for producing a Y-shaped steel sleeper with a fastening for a track plate of the type described in the introduction, which is characterized by the following method steps:

• Manufacture of the Y-shaped steel sleepers from double-T beams, two of which form a common rail base with their ends by welding the lower chords and upper chords of adjacent T beams, possibly with the insertion of stable, rigid spacers,
• Determining the position of the attachment points of a track plate relative to the outer edge of the steel sleepers,
• Fastening the bolts by means of stud welding on the previously determined fastening points and
• If necessary, mounting the track plates and inserting an anti-corrosion agent around the welding point of the bolts.

With these methods, the series production of Y-steel sleepers with ready-to-install ribbed plates of a commercial type can be increased considerably, especially if a coordinate welding machine is used for stud welding. This is understood to mean a machine that - controlled by hand or by computer - can approach any coordinate on a threshold or switch, relative to a spatially fixed reference point. It is no longer necessary to align the threshold correctly in a switch for assembly. By determining the position points on the basis of nomograms or grid dimensions, the fastening point of the screw bolts can be determined manually or by computerized calculation and control of the welding machines, and a stud welding device can be applied precisely. As a result, there is no need for intermediate assembly and subsequent partial disassembly to remove the switch. This also avoids turning the finished switch or individual threshold for the final welding of the rear sides of the ribbed track plates.

Furthermore, there are no longer any incorrect bores in sleepers, which would immediately result in rejection and / or laborious repair welding of the sleepers - if permitted at all. A mis-welded bolt can be removed locally and after grinding the The welding point can be replaced by another stud at the same location or in the target position next to it.
A sleeper head or sleeper end can be used as a reference point for a bolt, since the steel sleeper, unlike the wooden sleeper or concrete sleeper, can be manufactured with constant dimensions as standard.
Ideally, separately manufactured Y-steel sleepers can be connected to a turnout with a separately manufactured carriageway on the construction site or, if necessary, in a partial assembly workshop. The threshold can be prefabricated with stable spacers between the top and bottom chords of the double-T beams. These are particularly adapted to the beams and their loads, since the ribbed plate welded on according to the prior art is omitted as a spacer and as a stiffening component. Depending on the width of the straps or the width of the supports used or their moment of resistance or inertia or the width of the track plates, the supports can also be welded to the straps without gaps.

The thresholds can be designed in Y shape or in double Y shape, half Y shape or in a so-called Y-N shape.

Fig. 1

eine Draufsicht auf eine Gleisanlage mit Weiche,

Fig. 2

eine Seitenansicht einer Y-Stahlschwelle mit Schnitt durch einen Schienenstützpunkt und

Fig. 3

einen Schnitt durch eine weitere Ausführung eines Schienenstützpunktes.

Some exemplary embodiments of the invention will be explained in more detail with the aid of schematic drawings.
Show it

Fig. 1

a plan view of a track system with switch,

Fig. 2

a side view of a Y-steel sleeper with a section through a rail base and

Fig. 3

a section through another version of a rail base.

Figure 1 shows a track system with rails 11, 13, which are in track S along the track axis A and pass from a track with YN sleepers 1200 into a switch consisting of sleepers 1201 to 1207. The switch has additional tongue rails 14, 15; it has a radius R of 1200 m. In principle, the threshold 1200, like the other thresholds, consists of a middle double-T beam 2, two outer double-T beams 1 and short double-T beams 4 in between. Two beam ends 1, 2 and 1, 4 form a rail base P3, which is designed as a ribbed plate or base P7, which is designed as a sliding chair. With the exception of the threshold 1202, which has an additional element made of beams 2, 6, the thresholds 1201 to 1207 of the switch section between the dividing points 8 are designed similarly to the threshold 1200, except that the rail support points take into account the tongue rails 14, 15 and their displacement are trained differently. The tongue rails 14, 15 can be moved by rods 10 between the stops 9. With the help of the boundary conditions: track width S, track axis A, turnout radius R and given base point distance for known Y-steel sleeper dimensions, the positions of the Bases P3, P7, the z. B. can be calculated in a computer and transferred to a corresponding coordinate grid in a partial assembly plant for the switch section 8-8.

The attachment of a rib plate (track plate) 3 according to the invention, which could belong to the rail base P3, will be explained using the example of the threshold 12 in FIG. 2 similar to the threshold 1200.
Figure 2 shows a fastening as it is provided for a Y-steel sleeper switch 12 on a solid carriageway, for example asphalt bedding or concrete bedding. The fastening 49 shown on the left in FIG. 2 is located on the double T-beam 2 in the example of the threshold 1200, while the cut fastening shown in the right half in the sense of the threshold 1200 on the double T-beam 1 lies. The hook screws 17 with springs 18 for fastening the foot 23 of the rail 16 lie centrally between the supports 1, 2; they are anchored in a recess in the rib 25 of the rib plate 3. A damping plate 24 is arranged between the rail 16 and the rib plate 3. The ribs 25 of the rib plate 3 limit the lateral migration of the rail foot 23. Two plastic plates 19, 20 are arranged between the rib plate and the double-T beam consisting of the upper flange 22, lower flange 21 and web 5. These simulate a desired sink depth of a threshold - that is, an elastic behavior - when the rail 16 is loaded by a train. With the aid of a stud welding device, a screw bolt 36 was fixed to the shaft 27 to form a weld bead 28 connected to the top flange 22 of the double T-beam 1. The welding point is filled up to approximately the thickness of the insulating plate 20 within the passage 29 of this insulating plate with anti-corrosion agent 26 to cover the welding bead 28. With a little play, the screw shaft 27 is surrounded by an insulating bush 31 fitted tightly in hole 30 of the rib plate 3, the collar of which on the rib plate 3 rests. A disc spring assembly 34 is arranged between two disks 32 and is surrounded by a spring cap 33. Above the spring cap 33, a further washer is arranged on the screw bolt 36, which transmits its force to a spring assembly 34 through a self-locking nut 35 until the spring cap 33 comes into contact with the insulating bush 31. In this way, a pre-adjustable spring travel is visibly achieved from the outside. For reasons of corrosion protection, the screw bolt is provided with a cap 37 which contains condensation water openings 48.

Figure 3 shows a fastening of a ribbed plate similar to Figure 2, but as a fastening for a steel sleeper in ballast bedding. Here too, similarly to FIG. 2, the fastening 50 shown on the left belongs to a double T-beam 2 lying behind the double-T beam 1, while the fastening cut in the right-hand illustration belongs to the double-T beam 1.
The same numbering of the parts shows their identity. A short screw bolt 39 is welded onto the top flange 22 of the double T-beam 1; around the welding point in passage 46 an insulating plate 44, an epoxy resin 45 has been introduced as an anti-corrosion agent. The bolt 39 protrudes through an insulating bush 43 which is tightly inserted in hole 30 of the ribbed plate 3. For the transmission of the tightening torque of the nut 40 to the bolt 39, washers 41, 42 are provided which press the collar of the insulating bush 43 firmly onto the ribbed plate 3. For corrosion protection reasons, the screw bolt 39 is provided with a cap 38 which has condensation water openings 47.

A ribbed plate fastening corresponding to the situation in FIG. 3 was subjected to a fatigue strength test in a scissor lever vibration test. The sleeper consisted of two wide-flanged double T-beams in parallel in the support area of the rail with a profile height of 95 mm and a width of the belts of 140 mm, which were welded together at a distance of 20 mm. The spacers between the upper and lower belts were welded in between the upper and lower belts 100 mm below the area of the ribbed plate. With the help of the stud welding process, four bolts 39 for each rib plate with the thread M22 were welded onto the upper flange 22 of the double-T beam 1. An insulating plate 44 and then the rib plate 3 were first pushed over the screw bolts 39. The insulating plate was 8.5 mm thick and consisted of ethylene-vinyl acetate copolymer (EVA). Between bolt 39 and rib plates 3 was in hole 30 an insulating bush made of polyamide with 30% glass fiber reinforcement, which had 1 mm play with the screw bolt. The disks 41 were designed as spring washers; with the tightening torque of 250 Nm that was exerted on the nut, they pressed the insulating bushing onto the ribbed plate and thus onto the top of the threshold. Type UIC 60 was tested as a rail.

In the scissor lever swing test, an intermittent force was exerted on the rail head at an angle of 31 ° to the vertical. The sinusoidal pulsating force was applied with a load of approx. 100 kN / rail support and a variable frequency between 1 Hz and 5 Hz. At the same time a temperature of 50 ° was simulated by applying a heater to simulate the heating of the superstructure by irradiation and thus a possible dimensional change of the plastic parts. Under the load shown, which corresponds to that caused by a high-speed locomotive of the German Federal Railways, which traverses a track system with a curve radius of about 300 m at a high speed of 80 km / h or more.

After more than 3 million load changes, corresponding to an operating load of around 73 million tonnes or a four- to five-year operation with around 50,000 tonnes per day, it was found that with insignificant plastic deformation of the washers, the horizontal displacement of the ribbed plates outwards between 0.21 and was 0.25 mm.
After the endurance test, the welds of the bolts were subjected to an ultrasound examination and it was found that the weld was intact.

Claims (6)

1. Securement for a guide plate (3, P3, P7), provided with holes (30), on Y-shaped steel sleepers (12, 1200, 1207), which comprise double-T-shaped supports (1, 2, 4, 6), for a railway, including bushes (31, 43), which are fitted into the holes (30), as well as bolts (36, 39), the shanks of which protrude with clearance through bores in the bushes, and an insulating plate (19, 20, 44), which is disposed between the guide plate and the steel sleeper and is provided with openings (29, 46) for the bolts and the bushes, which correspond substantially to the size of the holes in the guide plate, characterised in that the bushes (31, 43) are insulating bushes formed from hard plastics material, and in that the bolts (36, 39) are bolts which are applied to the double-T-shaped supports at exact spacings from one another by means of bolt welding from the upper end of the sleeper.
2. Securement according to claim 1, characterised in that the openings (29, 46) are filled with an anti-corrosive agent (26, 45).
3. Securement according to one of claims 1 or 2, characterised by a spring (34) between the insulating bush (31) and a nut (35) on the bolt (36) as well as a sleeve (33), which surrounds the spring and serves to determine the spring tension.
4. Method of producing a points switch for a railway from Y-shaped steel sleepers, on which guide plates for the mounting of rails are disposed, characterised by the following method steps:

   - producing the Y-shaped steel sleepers (12; 1201-1207) from double-T-shaped supports (1, 2, 4, 6), which are welded together at their ends at defined spacings therebetween and form a rail supporting point (P3, P7) with two ends at a time, in the prescribed length corresponding to their points switch position;

   - calculating the position of the rail supporting points (P3, P7) on the steel sleeper relative to the points switch axis (A);

   - determining the position of the securing points for guide plates (3) relative to the rail supporting point (P3, P7) or respectively relative to a reference axis (A, X) on each support;

   - marking the securing points with a bolt welding appliance;

   - securing bolts (36, 39) from the upper end of the sleeper by means of bolt welding on the T-shaped supports in the securing points; and possibly

   - assembling the guide plates (3), introducing an anti-corrosive agent (26, 45) at the base of the bolts (36, 39), and subsequently assembling the premanufactured railway component parts (11, 13, 14, 15) on the sleepers of a portion (8-8) of the points switch corresponding to the length of conveyance.
5. Method according to claim 4, characterised by the use of a co-ordinate welding machine for securing the bolts (36, 39) on the steel sleepers (12; 1201-1207).
6. Method of producing a Y-shaped steel sleeper with a securement for a guide plate according to one of claims 1 to 3, characterised by the following method steps:

   - producing the Y-shaped steel sleepers (12; 1200-1207) from double-T-shaped supports (1, 2, 4, 6), every two supports of which form a common rail supporting point (P3, P7) with their ends by welding together the lower belts (21) and upper belts (22) of adjacent T-shaped supports, possibly with the introduction of stable spacer members, which are resistant to bending;

   - determining the position of the securing points for a guide plate (3) relative to the outer edge of the steel sleepers;

   - securing the bolts (36, 39) by means of bolt welding on the previously determined securing points; and possibly

   - assembling the guide plates (3) and introducing an anti-corrosive agent (26, 45) around the welding location (28) of the bolts (36, 39).

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