The invention relates to a machine for compacting a ballast bed of a track with a machine frame supported on rail-based running gears and a height-adjustable stabilising unit connected thereto, comprising a vibration drive and an axle with wheel flange rollers movable on rails of the track, whose distance to each other extending perpendicularly to the longitudinal direction of the machine can be varied by means of a spreading drive, as well as a roller clamp that can be pressed against the rails by means of clamping drives. The invention further relates to a method for operating the machine.
In order to produce or restore a predefined track geometry, tracks with ballast beds are worked on by means of a tamping machine. Specifically, the position of the track panel bedded in the ballast bed, which consists of sleepers and rails fastened to them by means of rail fastenings, is corrected. During this correction process, the tamping machine travels along the track and lifts the track panel to an overcorrected target position by means of a lifting and lining unit. The new track position is fixed by means of a tamping unit tamping the track. Sufficient and, above all, uniform load-bearing capacity of the ballast bed is an essential prerequisite for the stability of the track position in railway operation.
Usually a machine is therefore used to stabilise the track after a tamping process. The track is loaded with a static load and set in vibration locally with a so-called Dynamic Track Stabiliser (DGS). The vibration causes the grains in the granular structure to become mobile, allowing them to be shifted and rearrange themselves with higher compactness. The resulting ballast compaction increases the load-bearing capacity of the track and replicates track settlements caused during operation. The increase in lateral track resistance also implies compaction.
EP 0 616 077 A1 discloses a corresponding machine with a stabilising unit arranged between two rail-based running gears. The stabilising unit comprises wheel flange rollers which are movable on a track and transmit vibrations generated by means of a vibration drive to the track. During a stabilising process, the wheel flange rollers arranged on a shared axle are pressed against the inner sides of the rail head by means of a spreading drive in order to avoid track gauge play.
The object of the invention is to improve a machine of the kind mentioned above in such a way that weak spots of the track are detected during a stabilising process. A further object of the invention is to indicate a corresponding method.
According to the invention, these objects are achieved by the features of claims 1 and 8. Dependent claims indicate advantageous embodiments of the invention.
The spreading drive and/or the clamping drives are set up to apply a predefined variable horizontal load force to the rails, whereby a measuring device is arranged to detect a rail head deflection and/or track gauge change caused by the variable load force. When activating this device, a mechanical spreading force with a predefined progression is applied to the rails crosswise to the longitudinal direction of the machine and the resulting change to the rail head deflection and/or track gauge is measured. In this way, it can be determined by means of the stabilising unit whether the track panel is intrinsically stable. No separate track possessions are necessary for this inspection because the measurements are carried out in the course of the maintenance measures by means of the stabilising unit.
With the arrangement according to the invention, the respective rail is clamped at the rail head between the wheel flange rollers and the roller clamp. The clamping force acting on the rails through the roller clamp is harmonised with the spreading force. Spreading force and clamping force add up to the varied load force that acts on the respective rail in addition to the dynamic impact force of the vibration drive. Specifically, changes to this load force are achieved by varying the spreading force and/or the clamping force. The track gauge change caused by a change to the load force subsequently provides information about the condition of the respective rail fastening.
Compared to an intact track panel, a damaged or insufficiently fixed rail fastening causes a greater track gauge change when the horizontal load force changes. The detected track gauge change can thus serve as a parameter for the condition of the rail fastenings. Loose rail fastenings occur, for example, due to overloading or destruction as a result of incorrect maintenance. Wooden sleepers age due to bacterial infestation and weather-related influences, which can cause rail fastenings to loosen. A visual inspection is usually insufficient here.
In addition, track sections with defective rail fastenings are often not detectable with conventional track inspection vehicles because safety-relevant limits have not yet been exceeded. The present invention provides that the dynamic impact forces of the stabilising unit cause previously damaged rail fastenings to be detected as such. In particular, existing material cracks in rail fastening components are made more extreme, enabling immediate detection. This synergy effect results directly from the use of the stabilising unit according to the invention for inspecting the stability of the track panel. Known systems (Gauge Restraint Measuring System, GRMS) only measure a changed track gauge as a result of a spreading axle guided along the track with static transverse forces. There is no dynamic component that causes previously damaged rail fastenings to be detected.
In an advantageous embodiment of the invention, control signals, which cause a periodically changed load force, are stored in a control equipment for actuating the spreading drive and the clamping drives. The periodic change to the load force takes place at a frequency that is significantly lower than a vibration frequency of the vibration drive. The stabilising unit is normally operated at a vibration frequency between 30 Hz and 35 Hz. By contrast, the period of the variable load force is approx. 1 second, so that the frequency of 1 Hz is clearly below the vibration frequency. In this way, a disturbing influence of the vibration on the rail head deflection caused by the load force is avoided. The measured deflection values or track gauge changes can be clearly assigned to the periodic, low-frequency progression of the load force.
Advantageously, the measuring device is coupled to the axle of the wheel flange rollers. The track gauge is thus measured directly in the force axis of the spreading force acting on the rails, whereby the direct correlation between spreading force and track gauge is identified.
In a further embodiment of the invention, the measuring device is coupled to an evaluation device, with the evaluation device being set up to assess a rail fastening on the basis of the detected rail head deflection and/or track gauge change. The evaluation device enables an automated evaluation of the condition of the respective rail fastening.
In this context, it is advantageous if the evaluation device is set up to evaluate rail head deflections and/or track gauge values detected at a measuring point as a function of a progression of changed load values in order to assess a condition of rail fastenings positioned in the area of the measuring point. In this way, pairs of values of a load-displacement curve are recorded and compared in order to derive a state variable of the respective rail fastening.
A further improvement provides that a position determination unit is arranged for a location-specific detection of the rail head deflections and/or the track gauge change. The location reference achieved in this way facilitates a comparison between the measuring results and the positions of the respective rail fastenings of the track in use. The location-specific detection is also advantageous for documentation purposes.
In a further development of the machine, two stabilising units are arranged one behind the other, each stabilising unit comprising a measuring device for detecting rail head deflections and/or the track gauge change caused by the respective horizontal load force. This arrangement enables measurements with different load forces on the same spot during the machine's continuous forward travel. First, the front stabilising unit measures with a first load force. As soon as the rear stabilising unit reaches the same measuring point, a second measurement with a second load force takes place.
In the method according to the invention, the stabilising unit with the wheel flange rollers is first lowered onto the rails of the track. In the next step, the rails are subjected to a predefined variable horizontal load force by means of the spreading drive and/or the clamping drives, with a rail head deflection and/or track gauge change caused by the load force being detected by means of the measuring device in order to indicate a condition of a rail fastening. This additional use of the stabilising unit requires little effort. A compaction process that is to be carried out in any case is linked to the condition inspection of the rail fastenings.
In an advantageous embodiment of the method, the horizontal load force is periodically changed by means of a control equipment with a frequency that is lower than a vibration frequency of the vibration drive. Herein, a periodic control signal of the spreading drive and/or the clamping drives is modulated with a low frequency (e.g. 1 Hz), as it were, onto the vibration progression of the vibration drive. The periodically changed load force results from the spreading force of the wheel flange rollers and the clamping force of the roller clamp placed against the rails from the outside. This varied load force superimposes the impact force acting on the rails, which is caused by the vibration drive. This is particularly useful when operating a single stabilising unit.
In a further method variant, the rails are subjected to a first horizontal load force by means of the stabilising unit, with the rails being additionally subjected to a second horizontal load force by means of a further stabilising unit. In this method, both stabilising units are used to measure the track gauge as a function of the respective load force. By specifying different horizontal load forces, it is possible to detect the track gauge change, which provides information on the condition of the rail fastenings.
In a further development of the method, the machine is moved continuously along the track. When passing, different spreading forces are applied to the rails in the area of the respective rail fastenings, and the effects on the track gauge are measured.
For an automated evaluation, it is useful if the track gauge change is detected and evaluated as a function of the varied load force by means of an evaluation device. For example, an algorithm is set up in the evaluation device which compares track gauge changes to predefined limiting values.
In a further development of this method, rail head deflection values and/or track gauge values detected at a measuring point by means of the evaluation device are jointly evaluated as a function of different load force values. Here, pairs of values of a load-displacement curve are set in relation to each other in order to indicate the condition of the respective rail fastening.
A further improvement provides that a position determination unit is used to determine the position of the measuring device for a location-specific detection of the rail head deflections and/or the track gauge changes. The resulting location specificity achieved in this way enables an easy assignment to the respective rail fastening afterwards.
It is useful if evaluation data of a respective rail fastening is stored with reference to its location in order to assess its condition. The saved data is subsequently used to document the track inspection that has been carried out.
In the following, the invention is explained by way of example with reference to the accompanying figures. The following figures show in schematic illustrations:
The machine 1 shown in
Two stabilising units 10 are attached one behind the other in the longitudinal direction of the machine 11 to the machine frame 2 of the machine 1 shown. Furthermore, the machine 1 comprises a traction drive 12 and a measuring system 13 for detecting a track position as well as a cab 14 for operating staff. From a non-operating position, the respective stabilising unit 10 can be lowered onto the rails 6 by means of height-adjustment drives 15.
Each stabilising unit 10 has a vibration drive 16. Vibration is usually generated by means of rotating unbalanced masses. In addition, each stabilising unit 10 comprises an axle 17 aligned crosswise to the longitudinal direction of the machine 11 with wheel flange rollers 18. In the operating position, the stabilising unit 10 is movable on the rails 6 by means of these wheel flange rollers 18. A spreading drive 19 is arranged in the axle 17, by means of which the distance between the wheel flange rollers 18 can be changed.
According to the invention, the spreading drive 19 is set up to apply a predefined spreading force FS to the rails 6. Accordingly, the spreading drive 19 is not only intended to press the wheel flange rollers 18 against the inside of the respective rail head without play. In fact, the spreading force FS is predefined with a specific value, which is subsequently set in relation to a measured track gauge s or track gauge difference Δs. The spreading force FS is applied to the respective rail 6 from the inside.
The track gauge s or the track gauge difference Δs is measured by means of a measuring device 20. This comprises, for example, an electromechanical distance sensor coupled to the axle 17. In this case, a first component of the sensor is connected to a shaft portion, which is displaceably mounted in the direction of the axle and is connected to the left wheel flange roller 18. A second component of the sensor is connected to a displaceably mounted shaft portion of the right wheel flange roller 18. If the shaft portions are moved against each other by means of the spreading drive 19, the components of the sensor also shift towards each other, whereby a shifting path is measured. This shifting path corresponds to the track gauge difference Δs when the wheel flange rollers 18 are in contact with the rail heads.
The stabilising unit 10 shown in
In the clamping position, the clamping drives 23 exert a predefined clamping force FK on the rails 6 via the clamping rollers 22, which counteracts the spreading force FS. In this case, the clamping drives 23 and the spreading drive 19 are harmonised with each other by means of a control equipment 24 in such a way that a desired horizontal load force FB acts on each rail 6.
In an advantageous embodiment of the invention, the load force FB is periodically changed by means of the control equipment 24, as shown in
The frequency of the changed load force FB is significantly lower than the vibration frequency, which is normally within the range of 30 Hz to 35 Hz. Mass inertias are negligible at this frequency value. A load force FB acting alternately outwards and inwards also represents a useful variant. The rail fastenings 7 on the outside and inside of the rail are equally stressed.
The torsional moment must be absorbed via several rail support points. In the rail support points, a reactive moment is developed on the rail foot due to the torsion of the rail 6. The rail head deflects to such an extent until an applied moment Mt and a reactive moment Mr are of equal size. The applied moment Mt depends on the transverse force Y:
The reactive moment Mr (return moment) results from the vertical force Q and from hold-down forces FSkl of the rail fastenings 7, with a distance b resulting in the rail foot plane between the rail foot centre and a centre of gravity of a pressure distribution:
The forces or moments cause a rail head deflection ΔsL/R and a rail foot edge depression a. At the rail foot edge, an edge compressive stress σR occurs in the intermediate layer 25.
The forces acting on the stabilising unit 10 and on the rails 6 are explained in detail with reference to
Favourably, the evaluation device 26 is also fed with the current load application height h of the horizontal transverse force YL, YR (
It is also useful to automatically detect the sleeper positions (support points of the rails 6) in order to determine the sleeper spacing. The frequency of the progression of the horizontal load force FB (
The vertical force Q acting on the respective rail 6 is advantageously predefined with a periodic progression. In this case, the height-adjustment drives 15 are actuated with a periodic control signal in order to support the stabilising unit 10 with variable force against the machine frame 2. The frequency of the progression of the horizontal load force FB is adapted to the progression of the vertical force Q. In this way, different pre-stress levels when pressing the intermediate layers 25 together are taken into account. The tilting spring effect of the respective rail fastening 7 (spring rate of the intermediate layer 25) can then be monitored.
In the measurement shown in
In a first phase I, the load force FB equals zero. Spreading force FS and clamping force FK are equal so that the respective rail 6 is only clamped without transverse force acting on it. The progression of the impact force FV is shown with a thin solid line. In the first phase I, the effect of the impact force FV is distributed uniformly on both rails 6. Thus, half the impact force FV acts on each rail 6 as the resulting transverse force YL, YR.
In a second phase II, a modified spreading force FS is predefined, which results in a first load force FB1L, FB1R acting on the respective rail 6. Equivalent to predefining a modified spreading force FS, a modified clamping force FK can also be predefined. Predefining the resulting first load force FB1L, FB1R can also be useful in an equivalent way. For example, the spreading force FS and/or the clamping force FK are modified in a control loop until the predefined first load force FB1L, FB1R is reached.
In
In a third phase III, the control equipment 24 predefines a second spreading force FS2 that is higher than the first spreading force FS1. The respective clamping force FK remains unchanged so that the second load force FB2L. FB2R acting on the respective rail 6 is also directed outwards. The changed load force FB2L, FB2R can also be predefined by changing the assigned clamping force FK. With the load forces FB1L, FB1R, FB2L, FB2R of different sizes, the track gauge change s can be detected due to two different load conditions.
The transverse force Y1L, Y2L acting on the left rail 6 is the sum of forces of half the impact force FV and the left load force FB1L, FB2L. The sum of forces of half the impact force FV and the counteracting right load force FB1R, FB2R acts on the right rail 6 as transverse force Y1R, Y2R. To the outside, the two transverse forces Y1L, Y1R or Y2L, Y2R in turn add up to the total impact force FV, with the load forces FB1L, FB1R or FB2L, FB2R cancelling each other out in the track panel and resulting in the track gauge change s.
It is possible to draw conclusions about the quality of the rail fastenings 7 located at the measuring point already from the first track gauge difference Δs1. In particular, the difference Δs2 of the two track gauge values s1, s2 under different load conditions forms a parameter for assessing the respective rail fastening 7. Derived parameters are also informative, such as the slope of the track gauge progression as a function of the load changes.
For the location-specific detection of the track gauge change, the machine 1 usefully comprises a position determination unit 28. For example, a GNSS module is arranged on the roof of the machine 1. To determine the position of a current measuring point, the relative position of the stabilising unit 10 or the measuring device 20 is also evaluated with respect to the GNSS module. The position determination unit 28 can also be arranged directly on the stabilising unit 10 or on a rail-based running gear 3.
In a simple embodiment of the invention, the measuring results of the measuring device 20 are displayed in real time to an operator in the cab 14. The operator can react immediately and document a defective rail fastening 7. With the position determination unit 28, measuring data or evaluation data can be stored in relation to a position. In this way, the conditions of the rail fastenings 7 on the entire section of the track 4 being travelled on by the machine 1 are automatically documented. If necessary, a radio module 27 transmits the results to a central control in order to organise the repair of defective rail fastenings 7.
For an efficient and precise condition inspection of the rail fastenings 7, the machine 1 comprises two stabilising units 10 arranged one behind the other, as shown in
Position-related measurements of the respective track gauge s1, s2 are carried out by means of the two measuring devices 20. The detected track gauge values s1, s2 are fed to the evaluation device 26 in order to determine a position-related parameter. Due to the different load forces FB1L, FB1R, FB2L, FB2R, the difference of the track gauges s1, s2 are a meaningful indicator for the condition of the rail fastenings.
The measuring results thus provide a valid data basis for deriving parameters that serve to assess the condition of the respective rail fastening 7. In the simplest case, with the same increased spreading force FS, the track gauge difference Δs1 is evaluated compared to the normal track gauge s0. If the rail fastening 7 is defective, a higher track gauge difference Δs1 can be determined.
With the present dynamic measurement, any appropriately adapted Dynamic Track Stabiliser can be used to inspect the condition of the rail fastenings 7 directly on-site. The method is so accurate that individual loose fastenings 7 are detected. Due to the additional information about the condition of the rail fastenings of the rails 6, there is an increase in safety when opening the track 4 for traffic after a repair. During the stabilisation of newly laid tracks in particular, it frequently occurs that rail fastenings 7 have not yet been tightened firmly. The present invention is therefore particularly advantageous when maintaining newly laid tracks.
Number | Date | Country | Kind |
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A50591/2020 | Jul 2020 | AT | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2021/065378 | 6/9/2021 | WO |