As an important part of ballastless track, the installation quality of WJ-7 railway fastener system is crucial to the stability and safety of railway track. Standardized and accurate installation process can give full play to the performance advantages of the system and ensure the safe and smooth operation of trains.
Preparation before installation
Before installation, the quality and specifications of each component must be fully checked to ensure that the spring bars, T-bolts, rail pads, iron pads and other parts are not damaged or deformed, and the models meet the design requirements. At the same time, carefully clean the debris in the embedded casing to prevent dust, concrete residues, etc. from affecting the screwing and tightening effect of the T-bolts. In addition, professional installation tools such as torque wrenches and crowbars must be prepared, and technical briefings must be conducted for the installers to clarify the installation standards and procedures.
Installation process
Place the iron pad: accurately place the iron pad in the bearing groove of the ballastless track plate or sleeper, and ensure that the oblong hole on the iron pad is aligned with the position of the embedded casing to ensure the feasibility of subsequent track gauge adjustment.
Installation of rail pad: Select the appropriate type of rail pad (type A or type B) according to the line operation requirements, and place it steadily on the iron pad to ensure that the pad fits tightly with the surface of the iron pad without warping or displacement.
Insert T-bolt: Pass the T-bolt through the bolt hole on the iron pad and screw it into the embedded sleeve. The screwing process needs to be carried out slowly to avoid collision damage between the bolt and the sleeve, which affects the strength of the threaded connection.
Installation of spring bars and insulating blocks: First embed the insulating block into the corresponding slot of the iron pad, and then install the appropriate spring bar (type W1 for general sections and type X2 for sections with small resistance) on the T-bolt so that the buckling part of the spring bar acts accurately on the bottom of the rail.
Tighten the T-bolt: Use a torque wrench to tighten the T-bolt according to the specified torque to ensure that the spring bar reaches the designed buckling pressure. In general, the corresponding torque of the W1 spring bar needs to ensure that the buckling pressure of the spring bar is not less than the design standard to ensure the tightening effect of the rail.
Gauge and height adjustment: The height of the track can be adjusted by replacing height adjustment pads of different thicknesses, with a maximum adjustment of 30mm; the position of the iron pad can be moved by using the oblong holes of the iron pad to achieve a gauge adjustment of ±10mm. After the adjustment is completed, the installation status of each component and the bolt torque need to be checked again to ensure compliance with the standard.
Installation precautions
During the installation process, it is strictly forbidden to use hammering or other methods to forcibly install components to prevent damage to parts such as spring bars and bolts. At the same time, the tightening torque of the T-bolts needs to be strictly controlled. Excessive torque may cause bolt breakage or plastic deformation of the spring bar, and too small torque cannot guarantee the rail buckle pressure. In addition, after the installation is completed, the fastener system needs to be fully inspected to ensure that the insulating block, pad and other components are not misaligned, the spring bar buckling is in good condition, and the gauge and height errors are within the allowable range.