Device and Method for Building a New Ballastway for a Rail Line

Abstract

The present invention relates to a method and a device for building a new ballastway for an at least single-track rail line (100, 101) when there is initially no existing track. The new ballastway should have at least one PS layer (2) and one ballast layer (3), and the PS layer (2) is built up on a subgrade (1) and the ballast layer (3) is built up on the PS layer (2) in a continuous working process in a working direction (A). The PS layer (2) is built up by a PS layer-producing unit (20) (PSL unit), and the ballast layer (3) is built up by a ballast bed-producing unit (30), which is operated at a predefined distance behind the PSL unit (20) in relation to the working direction (A) and is equipped with a chain track or caterpillar track (31) for driving on the PS layer (2). The PSL unit (20) and the ballast bed-producing unit (30) are each supplied with the materials (K, S) needed to build up the PS layer (2) and the ballast layer (3) by means of an associated conveying device (12a, 12b) from at least one open-top wagon (10a, 10b), which is operated at a predefined distance in front of the PSL unit (20) in relation to the working direction (A).

Claims

1.-15. (canceled)

16. A method for building a new ballastway for an at least single-track rail line (100, 101) for an initially non-existing track, wherein the new ballastway comprises at least a PS layer (2) and a ballast layer (3) and the PS layer (2) is built on a ground subgrade (1) and the ballast layer (3) is built on the PS layer (2) in a continuous work sequence in a working direction (A), the method comprising: building the PS layer (2) by a PS layer finisher (20) (PSL finisher) and building the ballast layer (3) by a ballast bed finisher (30), the ballast bed finisher (30) operated at a predetermined distance behind the PSL finisher (20) in relation to the working direction (A) and provided with a chain or crawler running gear (31) for traveling on the PS layer (2), and supplying material (K) required for building the PS layer (2) and material (S) required for building the ballast layer (3) to the PSL finisher (20) and to the ballast bed finisher (30) by a respective correlated conveying device (12a, 12b) from at least one open-top car (10a, 10b), the at least one open-top car (10a, 10b) operated at a predetermined distance in front of the PSL finisher (20) in relation to the working direction (A).

17. The method according to claim 16, further comprising: storing the material (K) required for building the PS layer (2) in a first open-top car (10a) and transporting the material (K) from the first open-top car (10a) by the correlated conveying device (12a) to a receiving device (23) of the PSL finisher (20), and storing the material (S) required for building the ballast layer (3) in a second open-top car (10b) that is operated adjacent to the first open-top car (10a) and transporting the material (S) from the second open-top car (10b) by the correlated conveying device (12b) to a receiving device (33) of the ballast bed finisher (30).

18. The method according to claim 17, further comprising: embodying the conveying devices (12a, 12b) to be adjustable in length, position and/or angle position, and positioning a discharge end of the conveying device (12a, 12b) in relation to the receiving device (23, 33).

19. The method according to claim 18, further comprising: for producing a new ballastway for a double-track or multi-track rail line (101), employing a respective ballast bed finisher (30) for each of the tracks of the line to be constructed and employing the two or more ballast bed finishers (30) adjacent to each other, and supplying the material (S) required for building the respective ballast layer (3) to the ballast bed finishers (30) by a respective correlated conveying device (12b) from the at least one open-top car (10a, 10b), wherein preferably each ballast bed finisher (30) has correlated therewith its own open-top car (10b).

20. The method according to claim 16, further comprising: installing the material (K) required for building the PS layer (2) by the PS finisher (20) by an installation device (22), wherein the installation device (22) installs the PS layer (2) according to a predetermined profile for the PS layer (2) comprising height, width, shape, position, and slant; and installing the material (S) required for building the ballast layer (3) by the ballast bed finisher (30) by an installation device (32), wherein the installation device (22, 32) installs the ballast layer (3) according to a predetermined profile for the ballast layer (3), comprising height, width, shape, position, and slant.

21. The method according to claim 20, further comprising: surveying, leveling, and recording heights and lateral positions of the ground subgrade (1) and taking into consideration the heights and lateral positions of the ground subgrade (1) for predetermining the profile of the PS layer (2) and the profile of the ballast layer (3), wherein for surveying and recording the heights and lateral positions of the ground subgrade (1) preferably surveying and leveling devices (40a, 40b) are employed that are linked by at least one control unit with the installation devices (22, 32) so that the installation of the PS layer (2) with the predetermined profile of the PS layer (2) and the installation of the ballast layer (3) with the predetermined profile of the ballast layer (3) are performed in an automated manner.

22. The method according to claim 20, further comprising matching a travel speed of the PSL finisher (20), of the ballast bed finisher (30), and of the at least one open-top car (10a, 10b) and an installation speed of the PSL finisher (20) and of the ballast bed finisher (30) to each other, and matching a conveying speed of the conveying devices (10a, 10b) to the installation speed of the PSL finisher (20) and of the ballast bed finisher (20).

23. The method according to claim 20, further comprising: leveling and/or compacting the installed PS layer (2) by a leveling and/or compaction device (24) of the PSL finisher (20), wherein the leveling and/or compaction device (24) of the PSL finisher (20) is arranged behind the installation device (22), and/or leveling and/or compacting the installed ballast layer (3) by a leveling and/or compaction device (34) of the ballast bed finisher (30), wherein the leveling and/or compaction device (34) of the ballast bed finisher (30) is arranged behind the installation device (32).

24. The method according to claim 16, further comprising: loading the at least one open-top car (10a, 10b) with the materials (K, S) required for building the PS layer (2) and the ballast layer (3) by one or more trucks (15), wherein the one or more trucks (15) approach the at least one open-top car (10a, 10b) across the ground subgrade (1) from the front in relation to the working direction (A).

Description

[0044] It is shown in:

[0045] FIG. 1 a) a schematic side view and b) a plan view of a device in a work constellation according to an embodiment according to the invention for a single-track line prior to loading of the open-top cars;

[0046] FIG. 2 a) a schematic side view and b) a plan view of the device of FIG. 1 during loading of the open-top cars;

[0047] FIG. 3 a) a schematic side view and b) a plan view of a device in work constellation according to an embodiment according to the invention for a single-track line with alternative arrangement of the conveying device, prior to loading of the open-top cars;

[0048] FIG. 4 a) a schematic side view and b) a plan view of the device of FIG. 3 during loading of the open-top cars;

[0049] FIG. 5 a) a schematic side view and b) a plan view of a device in work constellation according to a further embodiment according to the invention for a double-track rail line prior to loading of the open-top cars;

[0050] FIG. 6 a) a schematic side view and b) a plan view of the device of FIG. 5 during Lit. TRL of PCT/EP2019/000219—First Named Inventor: Ralf archer—Assignee: archer Holding GmbH loading of the open-top cars;

[0051] FIG. 7 a) a schematic side view of a built new ballastway with track and two plan views b) of a built single-track and c) of a built double-track new ballastway with tracks;

[0052] FIG. 8 a) a schematic side view and b) a plan view of a device in work constellation according to a further embodiment according to the invention for a double-track line with a PSL finisher with leveling/compaction device, prior to loading of the open-top cars;

[0053] FIG. 9 a) a schematic side view and b) a plan view of the device of FIG. 8 during loading of the open-top cars;

[0054] FIG. 10 a) a schematic side view and b) a plan view of a device in work constellation according to a further embodiment according to the invention for a double-track line with a PSL finisher and a ballast finisher with leveling/compaction devices, prior to loading of the open-top cars;

[0055] FIG. 11 a) a schematic side view and b) a plan view of the device of FIG. 10 during loading of the open-top cars;

[0056] FIG. 12 a schematic cross section view of a single-track new ballastway;

[0057] FIG. 13 a schematic cross section view of the ground subgrade for the single-track new ballastway of FIG. 12 with a guideline arranged at this lateral edge:

[0058] FIG. 14 a plan view of a device in work constellation according to an embodiment according to the invention for a single-track line with a guideline arranged at the lateral edge of the new ballastway.

[0059] The new installation of trackbeds for track systems requires up to now two separate working steps for the construction of the PS layer and ballast layer when no complex construction trains that are track-bound are employed which complete the construction of the two layers with special devices at the head; this is associated with high costs.

[0060] FIG. 12 illustrates in simplified illustration the configuration of a single-track rail line 100 which comprises the trackbed of PS layer 2 and ballast layer 3 built on the ground subgrade 1. The railroad ties 4 (of which in the section illustration of FIG. 12 one can be seen) are recessed in the ballast bed 3 and the rails 5 are attached thereto. The ground subgrade 1 refers to the surface of the ground which has been appropriately machined with regard to flatness, slant, and profile-appropriate position. It can be seen in this context that the ground subgrade 1 has a roof-like slant in order to be able to discharge surface water reliably. The PS layer 2 which is built on the ground subgrade 1 comprises in the illustrated example a profile with corresponding roof-shaped slant while the ballast layer 3 installed thereon has a deviating profile with an approximately planar surface for the track of railroad ties 4 and rails 5.

[0061] The illustrated profiles of the PS layer 2 and of the ballast layer 3 are to be understood as an example. Modifications of the new ballastway to be produced with deviating profiles of the layers with regard to layer thickness, layer width, and layer slant as well as deviating heights and lateral positions of the new ballastway are encompassed by the claimed subject matter.

[0062] The method according to the invention that is performed inexpensively with a device according to the invention enables now the parallel installation of the PS and ballast layers 2, 3 continuously in a working direction without traveling with wheeled vehicles on the new PS layer 2, which is illustrated in an exemplary fashion with the aid of the embodiments in the FIGS. 1 to 11 and which is not possible with standard technologies, i.e., without the complex expensive track-bound construction trains. Due to the continuous installation in accordance with the invention without traveling across with wheeled vehicles, in particular the PS layer 2 is produced with the required homogeneity and the predefined profile essentially at the same time with the ballast layer 3 installed thereon, which is also provided uniformly with the predefined profile.

[0063] In the method according to the invention that relates to the simultaneous installation of the PS layer 2 and of the ballast layer 3, loading of the device with the materials K, S to be installed is realized from the ground subgrade 1, as illustrated in the Figures. The materials to be installed are in the following examples a sand-gravel mixture for the PSL and a stone ballast for the ballast layer but are not to be limited thereto. An alternative material for the PSL can be asphalt, for example.

[0064] FIGS. 1a,b show a truck 15 for loading which, in relation to the working direction A, is in front of the open-top car 10a, 10b in which the materials K, S are stored. In the work constellation of the device according to the invention, a PSL finisher 20 and behind it a ballast bed finisher 30 are arranged behind the open-top cars 10a, 10b in the illustrated embodiment and are all being moved uniformly forward approximately at a constant speed in the working direction A. In this context, the open-top cars 10a, 10b and the PSL finisher 20, which here each have a chain running gear 11, 21, travel on the ground subgrade 1 while the PS layer 2 is installed by the PSL finisher 20 on the ground subgrade 1 by means of the installation device 22 which, for this purpose, is arranged behind the chain running gear 21. The ballast bed finisher 30 following the PSL finisher 20 travels on the newly installed PS layer 2 and comprises for this purpose a suitable chain or crawler running gear 31 in order to avoid destruction of the PS layer 2.

[0065] The ballast layer 3 is installed in this context parallel and also continuously on the PS layer 2 by the ballast bed finisher 30 which for this purpose comprises a corresponding installation device 32 which is arranged behind the chain or crawler running gear 31.

[0066] Both installation finishers 20, 30 are supplied continuously with the required materials K, S wherein the material K, which is required for installation of the PS layer 2 and can be e.g. a gravel-sand mixture, is supplied to the PSL finisher 20 by means of a conveying device 12a from a correlated open-top car 10a in which the material K is stored. Open-top car 10a and the conveying device 12a are hidden in the side view; only the material K dropping from the discharge end of the conveying device 12a into the receiving box 23 of the PSL finisher 20 can be seen here. Correspondingly, the material S, which is required for installation of the ballast layer 3 and usually is stone ballast of a certain grain size, is supplied to the ballast bed finisher 30 by means of a further conveying device 12b from a correlated open-top car 10b in which the material S is stored. The supply of the materials is realized therefore in a material conveying direction M which is opposite to the working direction A and which enables loading of the device with the materials K, S from the ground subgrade 1 by means of trucks 15, which in the illustrated example are dump trucks. The truck 15 is placed or driven in front of the open-top car to be loaded, here the open-top car 10a correlated with the PSL finisher 20, in such a way that—as can be seen in FIGS. 2a,b—the material contained in the dump body of the truck 15 during dumping is transferred into the provided open-top car 10a in material conveying direction M. The continuous installation of the PS layer 2 and of the ballast layer 3 is not interrupted during this because the truck 15, which has been switched to idle after docking at the open-top car 10a, is moved during dumping by the open-top car 10a forwardly in the working direction A.

[0067] For starting the method according to the invention, when at the beginning only the ground subgrade is present, a first PSL track section whose length corresponds approximately to the length of the ballast bed finisher can be pre-manufactured with conventional earthmoving equipment as a starting support surface for the entire device. On this first PSL track section, the ballast bed finisher for forming the work constellation can be received in that, in front of it, the PSL finisher and the open-top cars with the respective conveying devices are arranged on the ground subgrade in order to start simultaneously the method according to the invention with the components of the entire work constellation of PSL finisher, ballast bed finisher, and open-top cars that are working in parallel.

[0068] The conveying devices 12a, 12b extend from the respective open-top car 10a, 10b to the corresponding finisher 20, 30 or to its receiving box 23, 33. The open-top cars 10a, 10b can comprise a supply hopper whose neck opens at or above the receiving end of the conveying device 12a, 12b. Also, the receiving boxes 23, 33 can be designed as supply hoppers in order to supply the respective installation device 22, 32 with the material directly or by means of a further conveying device.

[0069] The example illustrated in FIGS. 3a,b and 4a,b differs from the device illustrated in FIGS. 1a,b and 2a,b in the arrangement of the conveying devices 12a, 12b which may be the result of a different arrangement of the respective receiving boxes 23, 33 at the PSL finisher 20 and ballast bed finisher 30. As needed, a more uniform filling of the respective receiving box can be achieved by means of the different arrangement of the conveying devices and the variation of the discharge position that is achieved thereby.

[0070] In order to be able to utilize differently constructed finishers 20, 30 in a device according to the invention, either different open-top cars 10a, 10b can be provided, which differ in the arrangement of the correlated conveying device 12a, 12b in relation to their position transverse to the working direction, or the conveying devices 12a, 12b can be designed to be adjustable in relation to this position so that, depending on the arrangement of the open-top cars 10a, 10b and construction of the employed finishers 20, 30, the discharge end of the conveying device 12a, 12b can be positioned optimally in relation to the respective receiving device 23, 33.

[0071] Moreover, the conveying devices, even though this is not illustrated, can be of a telescoping and/or rotational configuration in order to provide a variability also with regard to length and/or angle position and to thus be able to ensure, even in case of deviating arrangement and/or distance of the open-top cars and finishers, the arrangement of the discharge ends above the respective receiving devices of the respective finishers.

[0072] In FIGS. 1a,b to 4a,b, the device comprises respectively an open-top car 10a, which is correlated with the PSL finisher 20, and an open-top car 10b, which is correlated with the ballast bed finisher 30, wherein the two open-top cars 10a, 10b are operated adjacent to each other. Of course, deviations from the illustrated examples are conceivable within the claimed subject matter which extends also to work constellations in which a single open-top car is employed that comprises separate sections or separate supply hoppers for the respective materials so that the conveying devices extend from the respective sections/supply hoppers of the individual open-top car to the correlated finishers. Embodiments in which the open-top cars are not operated adjacent to each other but one after the other or displaced relative to each other, wherein the devices in these work constellations comprise correspondingly adapted conveying devices, are also in accordance with the invention.

[0073] The exemplary illustration in FIGS. 7a,b shows how a single-track rail line 100 is completed, following the installation of the ballast layer 3 by means of the ballast bed finisher 30 of a device according to the invention, by arrangement of railroad ties 4 on the ballast bed 3 of the new ballastway, as needed, with introduction of fill ballast 3′ between the railroad ties 4, and by attachment of the rails 5 on the railroad ties 4. FIG. 7c shows a double-track rail line 101 in which the new ballastway comprises two parallel ballast beds 3 and which can also be produced by the method according to the invention with a device according to the invention.

[0074] FIGS. 5a,b and 6a,b show in this context an exemplary embodiment of a device according to the invention for building such a double-track new ballastway. From the plan views of FIGS. 5b and 6b it is apparent that the device employed for this purpose, in accordance with the two ballast beds 3 to be built, comprises two ballast bed finishers 30 which comprise each a chain or crawler running gear 31 for traveling on the PS layer 2 and are operated at a predetermined distance behind the PSL finisher 20 which here installs the entire PS layer 2 by itself. The required material is supplied here also to the PSL finisher 20 by a conveying device 12a from the correlated open-top car 10a which is arranged in the illustrated example between two open-top cars 10b in which ballast is stored and from where a conveying device 12b extends respectively to the respective ballast bed finisher 30. Loading of the open-top cars 10a, 10b is done here also by trucks 15 which, as shown in FIGS. 6a,b, transfer the material by dumping into the respective open-top cars 10a, 10b.

[0075] Deviations from the illustrated example are conceivable here also within the claimed subject matter. For example, an alternative can provide that for storage of ballast only one open-top car is employed which is then however provided with two conveying devices in order to supply the two ballast bed finishers with material. A further alternative for building a double-track new ballastway can provide that a single ballast bed finisher is employed that comprises two installation devices. Depending on the width of the new ballastway, also more than one PSL finisher can be employed, as needed. The two PSL finishers can then be operated also adjacent to each other and, by means of corresponding conveying devices, be supplied with the material required for installation by their own correlated open-top car or by a common open-top car.

[0076] Moreover, it is understood that for producing multi-track new ballastways, i.e., new ballastways with more than two tracks of the line, the number of employed ballast bed finishers, as needed also of the PSL finishers, and of the correlated open-top cars and conveying devices is to be matched appropriately. For example, a work constellation for a three-track new ballastway can provide for the parallel use of three ballast bed finishers adjacent to each other behind a single PSL finisher that manufactures the PS layer for the three-track new ballastway across its entire width, wherein four open-top cars, one for PSL material and three for ballast, are operated in front of the PSL finisher. In this context, a conveying device extends from the open-top car for PSL material to the PSL finisher and a respective conveying device extends to one of the ballast bed finishers, respectively, from the three open-top cars for ballast. Of course, alternative work constellations with regard to the number of finishers and open-top cars or the number of installation devices, which have been described above in connection with the double-track new ballastway, are also conceivable here and are encompassed by the claimed subject matter. The same applies to new ballastways for four or even more tracks.

[0077] In principle, it is provided in accordance with the invention that the individual device components are linked electronically so that the individual work sequences are performed automated and linked. For complete automation, the installation finishers can be provided in addition with electronic surveying and leveling devices so that height and lateral positions of the layers can be controlled mechanically/electronically/by GPS.

[0078] FIGS. 13 and 14 show for this purpose a guideline 40a as well as sensing devices 40b of the finishers 20, 30 as surveying and leveling device. The guideline 40a, which is embodied as a wire string, is stretched along the lateral edge along the projected new ballastway at a previously calibrated height and is used during the method as a sensing line for the finishers 20, 30. The installation finishers 20, 30 continuously sense the measurement during forward movement. In this context, the guideline 40a provides the baseline (height/lateral position) of the layer to be installed. In FIG. 13, the layers 2, 3 to be installed are illustrated in dashed lines wherein the guideline 40a which extends perpendicularly to the plane of illustration is to be understood only as an example in regard to the illustrated height which corresponds here to the surface level of the ballast layer 3 to be installed. As a function of the forward movement (travel length), the installation parameters of the respective layer profile, i.e., slant, height, width and the like, that has been previously electronically stored in the control unit of the finisher based on the plan documentation, are autonomously determined by the control unit of the respective finisher, i.e., automatically. Alternatively, a manual control of slant, thickness, width and the like can also be performed by a driver of the finisher along the guideline.

[0079] The provided profile of the respective layer that is dependent on the projected new ballastway and comprises parameters such as layer thickness, layer slant, and layer width, can be adjusted by the installation finishers by a manual and/or automated control manner. In case of the manual control manner, the installation device of the respective installation finisher is manually adjusted in accordance with the intended profile. In case of the automated control manner, the respective installation device is adjusted by signals of the control unit in which the parameters of the respective profile are stored.

[0080] Examples of further embodiments are illustrated in FIGS. 8a,b to FIGS. 11a,b. In FIGS. 8a,b and FIGS. 9a,b, the PSL finisher 20 has an additional leveling and compaction device, i.e., the compaction beam 24; in FIGS. 10a,b and FIGS. 11a,b the PSL finisher 20 shows the compaction beam 24 and the ballast bed finisher 30 has also a leveling or compaction device, namely also a compaction beam 34, in order to level and compact the installed PSL 2 or ballast layer 3, respectively.

[0081] The additional leveling and/or compaction devices 24, 34 are illustrated schematically here and are arranged behind the respective installation device 22, 23.

[0082] As illustrated in FIGS. 10b and 11 b, the compaction beam 24 of the PSL finisher 20 extends across the entire width of the installed PSL 2 in order to level and compact according to the predetermined profile. The width of the compaction beam 34 of the ballast bed finisher 30 corresponds to the width of the respective ballast bed or the respective ballast layer 3, i.e., in the illustrated example of the double-track new ballastway to half of the total width. In deviation from the illustration, the width of the ballast layer can also be smaller than half of the total width of the double-track ballastway.

LIST OF REFERENCE CHARACTERS

[0083] ground subgrade

[0084] PS layer

[0085] ballast layer

[0086] 3′ fill ballast

[0087] railroad tie

[0088] rail

[0089] 10a open-top car PSL material

[0090] 10b open-top car ballast

[0091] 11 crawler/chain running gear

[0092] 12a conveying device PSL material

[0093] 12b conveying device ballast

[0094] 15 truck

[0095] 20 PSL finisher

[0096] 21 crawler/chain running gear

[0097] 22 installation device

[0098] 23 receiving box

[0099] 24 compaction beam

[0100] 30 ballast bed finisher

[0101] 31 crawler/chain running gear

[0102] 32 installation device

[0103] 33 receiving box

[0104] 34 leveling/compaction device

[0105] 40a, 40b surveying and leveling devices

[0106] 100 single-track rail line

[0107] 101 double-track rail line

[0108] A working direction

[0109] M material direction

[0110] K PSL material

[0111] S ballast