Table 1 Weld joints allow geometric deviation mm
(8) After the long rails have been welded and accepted for welding, use multiple gantry cranes and hoist them to the long rail storage station. Long rails are stored in storage as follows:
1 Write the rail number and length of the long rail, and classify the stacking code;
2 The rail support pads are used between the layers of the long code rails with a spacing of 5 m. The rail support pads are aligned up and down and placed perpendicular to the rails of each layer;
3 When the hanging rails are slowed down, it is strictly forbidden to fall and collide, and the long rails are kept stable during lifting.
4 Main equipment and equipment (Table 2)
5 Labor Organization (Table 3) Table 3 Personnel organization during welding
Process content Short-track lifting and storage Optional rail and rail end straightening rail end descaling brush surface rail push welding rail welding head welding head welding head rough grinding head fine grinding long rail lifting and loading inspection and external Type detection
6 Quality requirements
(1) Number of type inspection operators before welding
3
3 (including 1 technician)
2
4
3
2
1
2
8 (including 1 command)
2 (also in charge of technical information)
30 people in total
In order to ensure the welding quality of the rails, before the formal welding, the welding process parameters of the welding machine are first adjusted, and the welding head is welded for type inspection under suitable process parameters, and the large-scale welding is carried out after the type inspection is passed. The type inspection is completed in accordance with the Technical Conditions for Rail Welded Joints (TB/T1632). The inspection items include 10 indicators, namely, drop hammer, static bending, fatigue, metallography, hardness, appearance, fracture, flaw detection, and tensile. And impact toughness, any of which failed to pass, need to be re-commissioned.
(2) Welding process control
After the type test is passed, the welding is carried out according to the welding parameters and must not be changed. Each welding head is monitored by computer process and automatically identified and judged. If it is not qualified, it should be sawed and re-welded. Each welding head must be normalized after welding to improve its structural structure and enhance its comprehensive mechanical properties. Finally, it must be tested for flaw detection and appearance. After 500 welding heads have been welded, periodic production inspections are carried out as specified.
7 Construction safety precautions
In addition to complying with the safety rules of the machine itself, the following matters should be noted during the welding process:
(1) During the rail pushing process, the speed should not be too fast to prevent the ball from being damaged or hitting the track;
(2) Personnel should avoid sparks from the splash and be fortified during welding;
(3) Smoking is prohibited in the normal fire area to prevent oxygen and acetylene from leaking and exploding;
(4) When hoisting the long rails, the gantry cranes should be hoisted evenly, and the long rails should always be kept at the same level. In order to prevent a gantry crane from failing, a total emergency switch must be provided.
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