Improvement of the fixing method of the walking rail track of the reclaimer in the second phase of the Huanghua Port storage yard

walking rail track of the reclaimer

walking rail track of the reclaimer

Abstract: This paper analyzes and studies the existing problems and shortcomings in the track-fixing method of the reclaimer in the second phase of Huanghua Port, and proposes a new self-made track installation and fixing device to solve the track loosening caused by the settlement of the track beam on the track installed on the soft foundation treatment basis. The problem.

Project Overview

The second phase of the storage yard in Huanghua Port covers an area of 330,000 square meters per month. It is equipped with 6 reclaimers, 1 stacker-reclaimer, 4 stackers, a rated reclaiming capacity of 6,000 tons per hour, and 5 track lines. strip 1200 m. The rail track of the second phase of the Huanghua Port is in operation, and the gaskets below it have the appearance of being squeezed out. The main reason is that the gaskets are loose and the pressure of the wheels causes the rails to sink, which causes the rail clamps to interfere with the bolts. In the case of low temperature, the pressure of each rail pressure plate on the whole track is not the same, and the contraction direction of the track tends to the side where the pressure of the rail pressure plate is tighter, resulting in the widening of the local track joints, and some widths It even reached about 3~4cm, exceeding the design standard by about 2cm, which caused serious safety hazards to the walking wheels of the large machine.

Cause Analysis

Considering the geographical environment and various factors, there are three specific reasons. One is that the track beam is installed on the soft foundation treatment, and the sinking is different in Chengdu. The track beams at the site of the event sank more severely; second, the outsourced construction was carried out once a year for inspection, maintenance, and fastening. After 2 months, the gaskets under the tracks were still loose. The pads are made of plastic and rubber products, the height-adjusting pads are thicker, and the pressure resistance is not enough. The third is that the fixing method of the track pressure plate has not been improved, causing the track to deviate.

Determine the implementation of the program transformation

1. Measure the entire track beam

By selecting a reference point on one side of the track, and using a level measuring instrument and a straightedge to measure at intervals of 10 meters, it can be seen from the measurement results that the maximum subsidence of the local track beam on the north side of the track beam is 80mm, which is also It is verified that the single-side operation and single-side coal stacking of the R5 reclaimer have a greater impact on the track beam.

2. Determination of track adjustment plan

First of all, determine the height of the backing plate according to the variation of the track beam, and determine the height of the bottom surface of the track according to the design standard for the track installation of the reclaimer.

Due to a large amount of change in the track beam, it is impossible to completely meet the standard after the track adjustment is completed. Therefore, a basic principle has been determined, that is, in the case of meeting the requirements of gauge, monorail curvature, joint height change, joint gap, etc., as much as possible It meets the requirements of the height difference between the two rails and the elevation change of the rails. Since there is no work on the track beams on both sides, the track beams basically remain unchanged, and the elevation is relatively high, while the track beams on both sides sink at an average of more than 50mm at the highest sinking point of the track beams from 650 meters to 790 meters. Affected by the fact that the anchor bolts are not long enough when the gasket is too high, the pad thickness of the track beam at this part can only meet the installation requirements through a smooth transition. Finally, it is determined that the base plate height of the left rail is determined on the basis of -10mm on the south side, and the height of the base plate on the north side is determined on the baseline of -20mm. The height of the backing plate, the average height difference on both sides is 10mm.

In order to solve the fundamental problem, the track must be adjusted straight, and the gasket must be combined with a steel plate with a certain strength and a plastic plate. In order to better ensure the gauge, both sides of the track pressure plate must be fixed.

The groove of the track pressure plate is 305mm, which is designed to fix the groove of the iron seat of the track; due to the preloading effect of the coal pile on the yard, the north side track beam is inclined to the north side, so in order to ensure the gauge of the track, The fixing grooves of local track beams need to be removed, and other fixing methods should be adopted. The track bolts are fixed on the track beam foundation with sulfur sand pouring after the track beam construction is completed.

In order to make the track and the track beam compact under the force of the wheel pressure, we have adopted the following installation method to fix the track.

Fastener 1: M24 grade 8.8 rail clamp bolts

Fastener 2: It is a curved flat pad <50-9 turnout>

Fastener 3: Elastic strip <50kgV type>

Fastener 4: It is a rail iron seat <50 rails> and all are standard parts.

Part 1 is the self-made fork pad; Part 2 is the self-made adjusting gasket with a total of 3 specifications; Part 3 is the plastic gasket, which is a standard part for railway use; Gasket;

The adjustment amount of the track is above 20mm. The left and right fixation of the track mainly depends on the inner side of fastener 4 to withstand the bottom of the track, and the outer side relies on the on-site welding of the fixed gasket piece 6 and piece 5. To the track bolts, and finally, achieve the purpose of fixing the track. When the track adjustment spacer is less than 20mm, the method of fixing the track pressure plate is to remove piece 5 and directly weld piece 6 on the fork pad piece 1, relying on the connection between piece 6 and piece 1 to reduce the force in the left and right directions of the iron seat of the track Pass it to the track bolts to achieve the purpose of fixing the track. The track backing plate adopts the form of a steel backing plate combined with a plastic backing plate, which not only ensures the strength requirements of the backing plate due to height adjustment but also has a buffering effect.

3. Project construction

①. Construction technology

The construction personnel is 10 people/per day, about 60 meters per day, and the planned construction period is 50 working days. During the production interval during the day, the single machine works normally on the track at night.

In order to ensure sufficient maintenance time and try not to delay production, mark the height that needs to be adjusted every 10 meters on each track, formulate the construction position according to the operation plan every day, and carry out the adjustment on the adjusted part and the unadjusted part every day The 10-meter over-adjustment section enables the single machine to safely walk there at night.

1. Start construction after taking safety precautions before construction.

2. According to the measurement data
Determine the height that needs to be adjusted below the track in the construction section, and make a record on site.

3. Remove track bolts
Use a T-wrench to remove the track fastening bolts, and remove the circlip and card. Since some bolts with serious corrosion can be trusted and removed after hot fire, pay attention to the implementation of fire prevention measures on-site.

4. Clean up coal deposits
After removing the track bolts within about 30m, lift a 25m track to a suitable height with two self-made scaffolding and an inverted chain, and start to clean the coal accumulation under the track without removing the track connecting plate, and then use a blower Blow off the dust under the track to ensure that there is no debris under the track.

5. Backing plate
According to the height required by the track, according to the height of the track adjustment, first add the fork pad 1, adjustment pad 2, and plastic adjustment pad 3 directly under the rail, and put down the rail; apply a mixture of lithium-based grease and mechanical lubricating oil to the rail bolts, to prevent further corrosion of the bolts; install the rail iron seat, elastic strips, arc flat pads, and bolts, and initially tighten the bolts with a track wrench.

6. Track elevation measurement and track gauge measurement
After the track adjustment is completed for 50 meters, measure the elevation and gauge of the track, and fine-tune the parts that exceed the standard.

7. Track straightening
Add pads according to the different gaps between the two sides of the fixed gasket piece 6 and the iron seat of the fixed track on the foundation to prevent the iron seat from moving left and right after being stressed. piece.

9. Clean up the site
Clean up the work site, so that the site is clean after work.

10. Bolt fastening and nut anti-corrosion
After one month of rolling by a single machine, tighten the bolts as a whole, then apply mixed oil on the track bolts, and cover the track bolts with protective caps.

11. Acceptance
After the track adjustment is completed, measure the rail top elevation, gauge, and track joint gap of the entire track, and check and accept after summarizing relevant parameters.

Conclusion and Significance

After running throughout the winter, the R5 reclaimer did not experience rail gnawing or abnormal noise during walking, and the joints of the track did not exceed the standard caused by local loosening of the track, which achieved the expected purpose. This transformation mainly solves the problem of track loosening caused by the settlement of track beams installed on the soft ground treatment foundation. It is innovative and provides a reference for dealing with the same problem in the future; it saves maintenance costs. It is necessary to carry out track inspection, maintenance and fastening once a year, which increases the maintenance cost and affects the operation time; after the implementation of the transformation plan, it can be guaranteed to be inspected and fastened once in 2 to 3 years, reducing the maintenance cost and affecting the production operation time; the field technicians have accumulated The experience has increased the on-site technicians’ knowledge of the basic conditions of the equipment and the experience in solving related problems; in the future equipment selection, the related problems of the equipment foundation have been put forward to meet the actual requirements of Huanghua Port.