Flexible Rail Fixing System Composition

1. Elastic rubber pad - The elastic rubber pad is made of synthetic rubber that is resistant to wear, shear, corrosion, extrusion, oxidation, UV radiation and oil. It is suitable for both indoor and outdoor use; there are grooves on the upper surface of the rubber pad, which gives the rubber pad a double bend and load curve; at the same time, it does not cause excessive internal stress in the rail itself. It can ensure that the bottom surface of the rail and the rubber pad are always in close contact, reducing the wear of the rubber pad. The reinforced rubber pad is inlaid with a galvanized reinforced steel sheet in the middle. The steel sheet gives the rubber pad lateral rigidity, which can prevent the rubber pad from sliding out of the bottom surface of the track and eliminate the possibility of longitudinal wear of the rail. These two phenomena are common in general rubber pads; the steel sheet is very thin and easy to roll up for transportation. The width of the steel sheet is proportional to the width of the rubber pad. The standard supply length of the rubber pad is 8-12 meters/roll, and the thickness of the rubber pad is 7mm (+0.5). Temperature range: -25℃~100℃. The use of rubber pads can make the positive pressure acting on the concrete foundation evenly distributed longitudinally to compensate for the unevenness between the contact surface of the rail and the steel beam. The evenly distributed wheel pressure can eliminate the local concentrated load and the fatigue stress generated by it; center the wheel pressure to reduce the bending stress on the rail; eliminate the wear between the rail and the upper surface of the steel beam; reduce the concave shape of the rail bottom and compensate for the angular error between the rail top surface and the wheel pressure load line; reduce the noise of the crane, reduce the impact on the building, and reduce the wear of the steel beam; extend the service life of the track system:

  2. Welding adjustable track pressure plate:This pressure plate is different from ordinary pressure plates. It has a special vulcanized rubber part on it, which presses the rail vertically with elastic force, and the size of the elastic force is controlled. The pressure plate can be adjusted laterally and has a self-locking function. The base is made by forging processing. The metal can improve its organizational structure and mechanical properties after forging. Generally, the mechanical properties of castings are lower than those of forgings of the same material. In addition, forging can ensure the continuity of the metal fiber organization, so that the fiber organization of the forging is consistent with the shape of the forging, and the metal streamlines are complete, which can ensure that the parts have good mechanical properties and long service life. Forgings produced by precision die forging, cold extrusion, warm extrusion and other processes are incomparable to castings.)The track flexible fixing system has strict requirements on the clamping force and lateral force of each set of pressure plates. Since the system requires the pressure plate base to be welded on the steel pad and to withstand a large alternating lateral force, the material and welding requirements of the base are very strict. The forging process is adopted, which has good safety performance and long service life. According to foreign technical requirements, the pressure plate base must be forged. It can be adjusted laterally; it has sufficient ability to resist lateral force; it is easy to install and readjust in the future, and the entire system should be maintenance-free; it can absorb "bow waves", eliminate stress on bolts, and allow the rails to move longitudinally under temperature changes; it can reliably fix the rails and rubber pads laterally to reduce the crawling of the crane; it eliminates the bending of the upper surface of the steel beam caused by load eccentricity, resulting in excessive wear of the elastic rubber pad and the upper surface of the steel beam.Welding adjustable pressure plate features:The pressure plate consists of two parts: the pressure plate clamp and the base. The pressure plate can be adjusted laterally.The pressure plate is fixed to the foundation by welding the base to the steel pad on the foundation surface.The clamp clamps the rails with a rubber nose, which is a synthetic rubber that is vulcanized and pressed onto the clamp.Use 1 or 2 bolts and nuts to fix the clamp to the clamp base. All parts are made of high-strength material (500-600N/mm2).Technical features:The pressure plate can be adjusted laterally during and after installation. The pressure plate has an adjustable range of 8-20mm depending on the type.The double-sided wedge connection can produce a self-locking function. The pressure plate can withstand lateral forces ranging from 40 to 200 kN depending on the type.The vulcanized rubber nose on the clamp has the following functions:Compensate for manufacturing tolerances of rails and beams;Eliminate the fatigue effect of bolts;Prevent bolts from loosening;Limit the movement of the rail axis;Pre-compressed rail bottom rubber pad.The vulcanization process ensures that the rubber nose adapts to various working conditions.Reduced noise and vibration.

3. Bolt-type pressure platecharacteristic:The pressure plate consists of two parts: the pressure plate clamp and the special gasket. The pressure plate can be adjusted laterally.The pressure plate is fixed to the supporting surface by bolts or weldable double-headed pins.The pressure plate clamp presses the rails with a rubber nose, which is a synthetic rubber that is vulcanized and pressed onto the pressure plate clamp.3000 Series Platens: With 1 or 2 special washers.All components are made of high-strength materials (500-600N/mm2).The clamp can be adjusted laterally during and after installation. Depending on the type, the clamp has an adjustable range of 5-20mm and a self-locking function. Depending on the type, the clamp can withstand lateral forces from 8.4 to 200kN.The vulcanized rubber nose on the clamp has the following functions:Compensate for the manufacturing tolerances of rails and steel beams and prevent the clamp bolts from loosening and breaking due to the "bow wave" effect;Eliminate the fatigue effect of the bolts, so that the rubber pad and the bottom surface of the rail are in close contact;Prevent bolts from loosening and pressure plate from rotating;Limit the movement of the rail axis and allow the rail to move longitudinally;Pre-compressed rail bottom rubber pad.The vulcanization process ensures that the rubber nose adapts to various working conditions.Reduced noise and vibration.

4. Track continuous welding:The rails are connected by welding, and the rails are welded together to form a continuous whole. The rails are laid on elastic rubber pads to evenly distribute the wheel pressure on the steel beam. The rail pressure plate should have an elastic clamping force to prevent the lateral movement of the rails and limit their longitudinal and vertical movement. An adjustable pressure plate is used, which can be adjusted laterally and has a self-locking function; the upper pressure plate is adhered with vulcanized rubber blocks, which press the rails with elastic force in the vertical direction, allowing the longitudinal elongation and shortening of the rails due to heating and cooling. In the crane track reconstruction project, how to deal with the original anchor bolts is the key to the reconstruction process. In the traditional rail fixing system, the anchor bolts directly bear the load transmitted from the track, and the stress conditions are poor. However, in the rails fixed by the flexible rail fixing technology, the anchor bolts only play the role of fixing the steel pad. The lateral force on the rail is mainly distributed to the steel pad through the pressure plate, and then transmitted to the anchor bolts through the steel pad. The anchor bolts do not directly bear the load transmitted from the track, and the stress conditions are greatly improved. This is the biggest difference between the flexible rail fixing technology and the traditional rail fixing technology. Therefore, the flexible rail fixing technology only needs to carry out necessary reinforcement for the loose and severely corroded anchor bolts according to the specific conditions of the site, and there is no need to re-drill the anchor bolts one by one. This reduces the amount of repair work, simplifies the construction process, and can greatly shorten the construction period.The rail flexible fixing technology is adopted to weld the rails into one piece and place them on the steel pad. The uneven foundation can be adjusted by the thickness of the cement, which fundamentally solves the common faults at the rail interface. During construction, the straightness requirements of the rails can be guaranteed by accurately controlling the elevation of the steel pad, and the construction accuracy is high.

5. Special cement for track:Its characteristics are: good early strength, high compressive strength; good fluidity after molding and no plastic shrinkage. This mortar is used for grouting of crane track grooves at port terminals and other large equipment foundations.