韓運(yùn)濤

摘要：預(yù)埋鐵座軌枕一般用于重載鐵路的鋪設(shè)。預(yù)埋鐵座枕的生產(chǎn)難度遠(yuǎn)高于較普通預(yù)留孔軌枕及預(yù)埋套管軌枕，由于其預(yù)埋鐵座部分突出于軌枕頂面，在預(yù)應(yīng)力放張時(shí)，鐵座與模具間會(huì)發(fā)生位移，故預(yù)埋鐵座固定裝置必須使鐵座與殼體間存在縫隙，或采用柔性可壓縮材料，為鐵座與模具間留有一定伸縮量。預(yù)埋鐵座的設(shè)計(jì)形式，使得生產(chǎn)此類軌枕時(shí)，定位精度與預(yù)埋鐵座周圍的密封成為主要難點(diǎn);現(xiàn)有定位方式雖能滿足預(yù)埋鐵座的定位精度，但密封性較差，預(yù)埋鐵座周圍混凝土的外觀質(zhì)量較差;另一突出的問(wèn)題是預(yù)埋鐵座軌枕的生產(chǎn)效率較低，人工成本浪費(fèi)嚴(yán)重。本文將圍繞預(yù)埋鐵件定位裝置的改進(jìn)研究，提供解決現(xiàn)有定位方式生產(chǎn)效率低下，鐵座周邊外觀質(zhì)量差的新思路，從而為所有預(yù)埋鐵座軌枕生產(chǎn)提供一種，生產(chǎn)效率更高，成本進(jìn)一步降低，外觀質(zhì)量更好的生產(chǎn)方式。

Abstract： The embedded iron seat sleeper is generally used for the laying of heavy-duty railway. The production difficulty of the embedded iron seat sleepers is much higher than that of the ordinary reserved hole sleepers and the embedded sleeve sleepers. Because the embedded iron seat part protrudes from the top of the sleepers， there will be displacement between the iron seat and the mold when the prestress is released， the fixed device of the embedded iron seat must keep the gap between the iron seat and the shell， or use flexible and compressible materials to leave a certain amount of expansion between the iron seat and the mold. The design form of the embedded iron seat makes the positioning accuracy and the sealing around the embedded iron seat become the main difficulties in the production of such sleepers; although the existing positioning method can meet the positioning accuracy of the embedded iron seat， it has poor sealing performance and poor appearance quality of the concrete around the embedded iron seat; another prominent problem is the low production efficiency of the embedded iron seat sleepers and serious waste of labor costs. This paper will focus on the improvement of the positioning device of embedded iron parts， and provide a new idea to solve the low production efficiency and poor appearance quality of the existing positioning mode， so as to provide a production mode with higher production efficiency， further cost reduction and better appearance quality for the production of all embedded iron seat sleepers.

關(guān)鍵詞：預(yù)埋鐵座定位裝置設(shè)計(jì);生產(chǎn)效率;外觀質(zhì)量;節(jié)約成本

0? 引言

目前行業(yè)內(nèi)采用的預(yù)埋鐵座固定裝置，均采用柔性可壓縮材料方式，使用此裝置的拆、裝工藝步驟較多，整套拆裝工藝占用行車較多，生產(chǎn)效率低;用于密封的膠圈損耗量大，人工用量大，成本高;因膠圈損壞變形導(dǎo)致預(yù)埋鐵座周圍混凝土凹凸不平，外觀質(zhì)量差。本文將通過(guò)總結(jié)以往定位裝置的缺點(diǎn)分析，通過(guò)設(shè)計(jì)新形式定位裝置，解決預(yù)埋鐵座軌枕生產(chǎn)效率低、成本高、外觀質(zhì)量差的一系列問(wèn)題。埋入式長(zhǎng)枕產(chǎn)品如圖1所示。

1? 現(xiàn)有定位裝置存在的問(wèn)題

1.1 生產(chǎn)效率低

由于預(yù)埋件與定位裝置間沒(méi)有縫隙，摩擦力大，脫模只能用行車吊住單根軌枕，然后用錘敲擊，緩慢將軌枕吊起，吊起過(guò)快易造成枕開(kāi)裂產(chǎn)生廢品，每模枕脫模時(shí)間不少于20分鐘。

膠圈變形、損壞，灰漿粘在膠圈凹槽，不清理干凈無(wú)法進(jìn)行預(yù)埋件安裝，清理工作非常耗費(fèi)時(shí)間，膠圈清理、更換時(shí)間不少于20分鐘。

預(yù)埋件頂絲位置空間狹小，不能采用電動(dòng)工具提升裝、卸效率，且數(shù)量很多，每模8根枕;每根枕4個(gè)預(yù)埋鐵座，每個(gè)鐵座2條頂絲，每模共有頂絲64條，均需用普通扳手拆除，4人拆除需、安裝共需20分鐘。預(yù)埋件頂絲如圖2所示。

預(yù)埋件安裝后，須由質(zhì)檢人員逐根對(duì)預(yù)埋件的大小軌距進(jìn)行測(cè)量檢驗(yàn)，合格后進(jìn)行最后緊固，每模耗費(fèi)時(shí)間不小于15分鐘。