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Chinese Journal of Engineering Design  2025, Vol. 32 Issue (4): 542-549    DOI: 10.3785/j.issn.1006-754X.2025.05.103
Mechanical parts and equipment design     
Development of new rope saw cutting equipment for ballastless track of high-speed railway in operation
Liye LIU(),Zhan CHEN(),Xinhui HE,Jiangjiang ZHU,Xiangxiang WU
China Railway Siyuan Survey and Design Group Co. , Ltd. , Wuhan 430063, China
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Abstract  

After the operation of China's high-speed railway, the geometric shape of the ballastless track structure on some lines has change to different degrees due to the long-term dynamic load of trains and the complex service environment, resulting in poor smoothness of the lines and seriously affecting the safe operation of trains. To solve this problem, by analyzing the existing restoration technologies and the functions of rope saw cutting equipment, and combining the characteristics of "restricted space" and "skylight point" short-time operation in the high-speed railway maintenance, the functional requirements of rope saw cutting equipment for the geometric shape restoration of ballastless track structures were proposed. A new multi-functional rope saw cutting equipment that could achieve lightweight modularity, autonomous movement, non-segmented horizontal cutting and bi-directional conversion cutting was developed and successfully applied in engineering practice. The results showed that the maximum static stress and displacement of the new rope saw cutting equipment were 94.5 MPa and 2.1 mm, both less than the allowable values (235 MPa and 4 mm). The first five natural frequencies of the equipment were significantly different from the standard vibration frequency of the main motion motor at 25 Hz, indicating that it had good static and dynamic characteristics. The comprehensive construction efficiency of the new rope saw cutting equipment was approximately twice that of the existing equipment, and its cutting accuracy and operational stability met the design requirements. The designed rope saw cutting equipment provides a convenient and efficient cutting tool for the ballastless track structure disintegration of high-speed railways in operation, which is of great significance for quickly restoring the alignment of high-speed railway and ensuring the normal and safe operation of trains.



Key wordshigh-speed railway in operation      ballastless track      line smoothness      rope saw cutting equipment      engineering application     
Received: 09 January 2025      Published: 01 September 2025
CLC:  TH 69  
Corresponding Authors: Zhan CHEN     E-mail: 1303599585@qq.com;245039071@qq.com
Cite this article:

Liye LIU,Zhan CHEN,Xinhui HE,Jiangjiang ZHU,Xiangxiang WU. Development of new rope saw cutting equipment for ballastless track of high-speed railway in operation. Chinese Journal of Engineering Design, 2025, 32(4): 542-549.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.05.103     OR     https://www.zjujournals.com/gcsjxb/Y2025/V32/I4/542


运营高铁无砟轨道用新型绳锯切割设备的研制

我国高铁开通运营后,因受到列车长期动载作用和复杂服役环境的影响,部分线路的无砟轨道结构几何形态出现了不同程度的变化,导致线路平顺性不佳,严重影响列车安全运行。为解决这一难题,通过分析现有修复技术和绳锯切割设备的功能,基于高铁运维的“受限空间”和“天窗点”短时间作业特点,提出了无砟轨道结构几何形态修复用绳锯切割设备的功能需求,研制了一款可实现轻质模块化、自主移动、不分段水平切割及双向转换切割的新型多功能绳锯切割设备,并成功应用于工程实践。结果表明:新型绳锯切割设备的最大静态应力和位移分别为94.5 MPa和2.1 mm,均小于允许值(235 MPa和4 mm),其前5阶固有频率与主运动电机的标准振动频率25 Hz相差较大,说明该设备具有良好的静动态特性。新型绳锯切割设备的综合施工效率较现有设备约提高了1倍,其切割精准性和运行稳定性均满足设计要求。所设计的绳锯切割设备为运营高铁无砟轨道结构解离提供了便捷高效的切割工具,对快速恢复高铁线路线形以及保障列车正常安全运行具有重要意义。


关键词: 运营高铁,  无砟轨道,  线路平顺性,  绳锯切割设备,  工程应用 
Fig.1 Existing rope saw cutting equipment and its engineering application
Fig.2 Operating principle of existing rope saw cutting equipment
Fig.3 Overall design scheme of new rope saw cutting equipment
Fig.4 Structure composition of electrical control system
Fig.5 Structure composition of main motion system
Fig.6 Structure composition of feed motion system
Fig.7 Structure composition of tension system
Fig.8 Structure composition of bidirectional cutting conversion system
Fig.9 Finite element model of new rope saw cutting equipment
Fig.10 Stress cloud map and displacement cloud map of new rope saw cutting equipment
Fig.11 Second-order modal vibration mode of new rope saw cutting equipment
阶数固有频率/Hz振型描述
17.3×10-4平动
272.3YOZ平面绕X轴弯摆
376.7YOZ平面绕X轴弯摆
490.3XOZ平面绕Y轴弯摆
5104.1YOZ平面绕X轴弯摆
Table 1 Natural frequencies and vibration modes of the first five orders of new rope saw cutting equipment
Fig.12 Assembly diagram of new rope saw cutting equipment
Fig.13 On-site construction effect of new rope saw cutting equipment
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