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1、High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护-Vossloh HSG-City Grinding Machine 福斯罗城轨高速打磨车,1,2,High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护,Content 内容,The main problems and status of rail maintenance in UTS 城市轨道交通中钢轨的主要问题及维护现状High Speed Grinding(HSG)technology 高速打磨技术Vossloh and the core technolog
2、y advantages of HSG 福斯罗公司及高速打磨技术的核心优势,+,+,+,3,High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护,Content 内容,The main problems and status of rail maintenance in UTS 城市轨道交通中钢轨的主要问题与维护现状Influence factors of the wheel/rail relationship in UTS 城市轨道交通中影响轮轨关系的因素Problems and challenges of rail maintenance 钢轨维护遇
3、到的问题和挑战Existing maintenance methods and effects 现有的钢轨维护手段和维护效果High Speed Grinding(HSG)technology 高速打磨技术Vossloh and the core technology advantages of HSG 福斯罗公司及高速打磨技术的核心优势,+,+,-,Influence Factors of the wheel/rail relationship in UTS 城市轨道交通中影响轮轨关系的因素,Rail vehicle 车辆Load 载重Speed 速度 Line geometry 线路几何尺
4、寸Welding joint 钢轨焊接接头,Rail 钢轨 Fastening systems 扣件Rail sleeper 轨枕Track subgrade 路基Environment 环境,4,5,High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护,Inhalt 内容,The main problems and status of rail maintenance in UTS 城市轨道交通中钢轨的主要问题及维护的现状Influence factors of the wheel/rail relationship in UTS 城市轨道交通中影响轮
5、轨关系的因素Problems and challenges of rail maintenance 钢轨维护遇到的问题和挑战Existing maintenance methods and effects 现有的钢轨维护手段和维护效果High Speed Grinding(HSG)technology 高速打磨技术Vossloh and the core technology advantages of HSG 福斯罗公司及在高速打磨技术的核心优势,+,+,-,Problems and challenges of rail maintenance钢轨维护遇到的问题和挑战,Line mileag
6、e rapid growth 线路里程迅速增长Faster running speed 速度越来越快Increased Locomotive traction force(shear force)机车牵引力不断提高（剪切作用力增大）Shorter departure time 发车间隔越来越短,Increased load 载重量增大 Corrugation causes traffic noise 波磨引起行车噪音 Rolling contact fatigue crack leads to shorten the service life of rail 滚动接触疲劳裂纹导致钢轨使用寿命缩
7、短 Less maintenance time(3-4 hours)维护天窗少（3-4小时）,6,7,Corrugation 波磨（北京地铁6号线）,Head checks 疲劳裂纹（鱼鳞纹）,Problems and challenges of rail maintenance 钢轨维护遇到的问题和挑战 Common Railway Problems 常见的钢轨问题,8,High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护,Content 内容,The main problems and status of rail maintenance in UT
8、S 城市轨道交通中钢轨的主要问题及维护的现状Influence factors of the wheel/rail relationship in UTS 城市轨道交通中影响轮轨关系的因素Problems and challenges of rail maintenance 钢轨维护遇到的问题和挑战Existing maintenance methods and effects 现有的钢轨维护手段和维护效果High Speed Grinding(HSG)technology 高速打磨技术Vossloh and the core technology advantages of HSG 福斯罗公
9、司及在高速打磨技术的核心优势,+,+,-,9,Linie 6 gemessen 0,25 mm!波磨深度0.25 mm,Traditional grinding maintenance 传统打磨维护Average grinding speed 5-8km/h 平均打磨速度5-8km/hThere are Facets after grinding 打磨后存在刻面Can lead to short wave irregularities 可导致短波不平顺Irregularity wave length is related to the grinding speed 不平顺波长与打磨速度有关,E
10、xisting maintenance methods and effects for rails 现有的钢轨维护手段和效果,10,To produce big smock 产生烟尘较大（烟雾和粉尘）Can be harming the health of workers 会影响作业人员健康Rails cleaning 轨道清洗(金属粉尘堆积可能导致绝缘接头失效)Working noise 作业噪音,Existing maintenance methods and effects for rails 现有的钢轨维护手段和效果 Cleanliness of existing maintenanc
11、e methods for rails 现有的钢轨维护手段的清洁性,11,High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护,Content 内容,The main problems and status of rail maintenance in UTS 城市轨道交通中钢轨的主要问题及维护的现状High speed grinding(HSG)technology高速打磨技术Rail defects and necessity for rail preventive grinding 钢轨病害和钢轨预防性打磨的必要性High speed grindi
12、ng 高速打磨Promote of HSG in Germany and worldwide references of HSG-city 高速打磨在德国的推广和城铁高速打磨在其他国家的应用Introduction of HSG technology 高速打磨技术介绍Technical data of HSG-city 高速打磨的技术数据Vossloh and the core technology advantages of HSG 福斯罗公司及在高速打磨技术的核心优势,+,+,-,12,Picture size 4,2 X 7,1 cm,Picture size 4,2 X 7,1 cm,
13、Picture size 4,2 X 7,1 cm,Corrugation and slip waves increase noise and vibrations.The comfort of travellers and neighbours decreases,on the other hand increasing dynamic forces damage the superstructure and rolling stock.波磨和滑波的病害增加了城铁列车通过时的噪音和震感，附近居民的生活也受到影响，乘客的舒适度也会降低。另一方面，增加了动态力压对基建和机车的伤害。,Rollin
14、g contact fatigue is a material transformation.A hardened surface layer develops and leads to surface cracks(head checks and squats).The ultimate consequence is rail fracture.接触性疲劳损害是一种物质转化。硬化表面层加深并且导致表面伤害裂缝，鱼鳞伤损等。最终可能导致钢轨断裂。,Rail pollution and rust corrupt the rail/wheel contact.Irregularities in t
15、raction and signalling harm the operating process and safety.附着于钢轨表面的污染物和铁锈腐败等阻碍了轮轨正常接触。打滑影响牵引力的充分释放，错误的信号显示危及行车安全,Rail defects and necessity for rail preventive grinding 钢轨病害和钢轨预防性打磨的必要性Rail defects 钢轨病害,波磨,鱼鳞纹,表面附着物,Rail defect:Headcheck 钢轨病害：鱼鳞纹Defect development 钢轨病害的发展过程,13,14,The Magic Wear Ra
16、te神奇的钢轨磨损率,The development of all common rail defects is non-linear 所有常见的钢轨损害的发展都是非线性的Goal:Maximize Rail Life Cycle by removing less material in shorter grinding cycles 目标：通过更频繁的打磨，每次仅去除少量钢轨表面材质，最大限度延长钢轨的使用寿命Optimum:Removal of the hardened surface layer before defects develop 最优方式：在伤损形成前磨削掉表面硬化层,bas
17、ed on:J.Kalousek,E.Magel:The magic wear rate.Railway Track&Structure,March 1997,pp.50-52.,No grinding无打磨,Common preventive grinding常见预防性打磨,Corrective maintenance修正性打磨,HSG preventive grinding预防性钢轨打磨,Rail defects and necessity for rail preventive grinding 钢轨病害和钢轨预防性打磨的经济效益Necessity for rail preventive
18、 grinding 钢轨预防性打磨的经济效益,Need HSG preventive grinding需要HSG预防性打磨,15,High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护,Content 内容,The main problems and status of rail maintenance in UTS 城市轨道交通中钢轨的主要问题及维护的现状High speed grinding(HSG)technology高速打磨技术Rail defects and necessity for rail preventive grinding 钢轨病害和
19、钢轨预防性打磨的必要性High speed grinding 高速打磨promote of HSG in Germany and worldwide references of HSG-city(without China)高速打磨在德国的推广和城铁高速打磨在其他国家的应用Introduction of HSG technology 高速打磨技术介绍Technical data of HSG-city 高速打磨的技术数据Vossloh and the core technology advantages of HSG 福斯罗公司及在高速打磨技术的核心优势,+,+,-,High speed gr
20、inding 高速打磨,16,work speed作业速度HSG-2:80km/h HSG-City:60km/hscope of grinding between打磨范围:+45-70amount of once grinding单次打磨量:rail surface roughness after grinding打磨后轨面粗糙度：8 mdust recovery over 90%,dont need to clean the track灰尘回收率：90%以上,无需清洗道床 noise emissions 作业噪音排放：65-85dblow production cost 生产成本低（无动力
21、）no need to remove the signal device无需拆卸线路信号装置,如计轴器easy transportation of changing grinding line(no need transition line)转线运输方便（无需渡线）much flexible(with different tractors)作业组织灵活（连挂不同牵引车：轨道车、公铁两用车）,HSG-2 高速打磨车&HSG-City 城铁高速打磨车,High speed grinding 高速打磨,17,18,High Speed Maintenance for Rails 城市轨道交通钢轨的高
22、速维护,Content 内容,The main problems and status of rail maintenance in UTS 城市轨道交通中钢轨的主要问题及维护的现状High speed grinding(HSG)technology高速打磨技术Rail defects and necessity for rail preventive grinding 钢轨病害和钢轨预防性打磨的必要性High speed grinding 高速打磨Promote of HSG in Germany and worldwide references of HSG-city(without Ch
23、ina)高速打磨在德国的推广和城铁高速打磨在其他国家的应用Introduction of HSG technology 高速打磨技术介绍Technical data of HSG-city 高速打磨的技术数据Vossloh and the core technology advantages of HSG 福斯罗公司及在高速打磨技术的核心优势,+,+,-,Commercial operations in Germany since 2008 自2008年，高速打磨技术在德国开始商业性运营Tracks ground with HSG in Germany 在德国应用高速打磨技术进行打磨作业 Mo
24、st of Germanys main corridors are machined with HSG since 2012 自2012年，德国多数的运营线路应用了高速打磨技术Standard for grinding on slab track and in tunnels 打磨技术可应用于板式钢轨和隧道内的打磨作业,Promote of HSG in Germany and worldwide references of HSG-city(without China)高速打磨在德国的推广和城铁高速打磨在其他国家的应用Promote of HSG in Germany 高速打磨在德国的推广,
25、19,20,from 2008 Germany 德国 Duesseldorf 杜塞尔多夫 Stuttgart 司图加特 Denmark 丹麦 Coppenhagen 哥本哈根,Promote of HSG in Germany and worldwide references of HSG-city(without China)高速打磨在德国的推广和城铁高速打磨在其他国家的应用Worldwide references for HSG-City 城铁高速打磨在其他国家的应用,2015,1-2015,2,2015,1-2015,2,References in China中国打磨业绩,HSG-2,2
26、1,22,HSG-City,References in China中国打磨业绩,Beijing Metro 北京地铁Line 6 6号线 Line 15 15号线Line 14 14号线 Changping line 昌平线Line 7 7号线2015-2016,23,HSG-City,References in China中国打磨业绩,Guangzhou Tram 广州有轨电车海珠线（2016.1，3km）,24,HSG-City,References in China中国打磨业绩,Harbin Metro 哈尔滨地铁（2015.10，单线35km）,25,High Speed Mainte
27、nance for Rails 城市轨道交通钢轨的高速维护,Content 内容,The main problems and status of rail maintenance in UTS 城市轨道交通中钢轨的主要问题及维护的现状High speed grinding(HSG)technology 高速打磨技术Rail defects and necessity for rail preventive grinding 钢轨病害和钢轨预防性打磨的必要性High speed grinding 高速打磨Worldwide promote of HSG in Germany and worldw
28、ide references of HSG-city 高速打磨在德国的推广和城铁高速打磨在其他国家的应用Introduction of HSG technology 高速打磨技术介绍Technical data of HSG-city 高速打磨的技术数据Vossloh and the core technology advantages of HSG 福斯罗公司及在高速打磨技术的核心优势,+,+,-,26,Passive driven grinding stones 被动驱动砂轮Passive adaptation to rail cross profile 被动适应钢轨横向廓形Optimiz
29、ation of longitudinal profile 纵面廓形最优化Constant material removal 恒定的磨削量High working speed 高打磨作业效率Over heating of rail impossible 避免钢轨过热,Principle of HSG 高速打磨 磨石工作原理,Introduction of HSG technology高速打磨技术介绍,电机主动驱动砂轮,27,High Speed Grinding is designed to work as a regular train 将打磨车视作一辆正常行驶的列车，边行驶边打磨No tr
30、ack preparation,e.g.dismantling of track installations like axle counters 打磨前无须拆除轨道装置，如：计轴器No extra work after grinding,e.g.cleaning of insulated rail joints 打磨作业后没有额外的工作，如：清理绝缘接头（作业后无需清洗轨道）No safety preparation of the track and safety personal required 没有特殊的安全防护要求，不需要设置现场防护员Changing of grinding con
31、sumables from inside of the machine 在打磨车内部更换磨石Neighbouring tracks keep running regular traffic 相邻轨道可保持常规的运营状态Higher flexibility in planning of grinding work 更灵活的安排打磨计划。Less traffic disruption and more effective use of track possession 更少干扰正常运营与更高的打磨效率,Characteristics of HSG 高速打磨特点,Introduction of HS
32、G technology高速打磨技术介绍,Grinding done with HSG-Light machine 应用高速打磨车轻型，进行打磨作业Noise reduction on test track for rolling stock homologation 车辆认证进行钢轨降噪测试,28,Before grinding8 days after6 month afterTSI limit,Wave length,Rail Roughness Level,Acoustic grinding in Austria 澳大利亚的降噪打磨,Introduction of HSG technol
33、ogy高速打磨技术介绍,29,High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护,Content 内容,The main problems and status of rail maintenance in UTS 城市轨道交通中钢轨的主要问题及维护的现状High speed grinding(HSG)technology 高速打磨技术Rail defects and necessity for rail preventive grinding 钢轨病害和钢轨预防性打磨的必要性High speed grinding 高速打磨Worldwide prom
34、ote of HSG in Germany and worldwide references of HSG-city 高速打磨在德国的推广和城铁高速打磨在其他国家的应用Introduction of HSG technology 高速打磨技术介绍Technical data of HSG-city 高速打磨的技术数据Vossloh and the core technology advantages of HSG 福斯罗公司及在高速打磨技术的核心优势,+,+,-,30,Technical Data 技术参数,Working speed 25-60 km/h 工作速度25-60km/h2 Mag
35、azines,each 2 rows,12 Grinding stones per rail(overall 48 grinding stones)两个打磨架，每个有两排打磨石，一排有12个打磨石（共48个打磨石）Approx.0,01 to 0,02 mm material removal 磨削量：每遍通过约0.01mm0.02mmRoughness 8 m 粗糙度 8 mRange approx.40 km nonstop 40km无中断打磨,Technical data of HSG-City高速打磨的技术数据,31,Core technology advantages of HSG-c
36、ity-Prevention城铁高速打磨的核心技术优势通过精细的去处钢轨表面变脆的硬化层延长钢轨使用寿命,mainly for preventive grinding(lower maintenance costs)以预防性打磨为主要目的（可延长50%-300%的钢轨使用寿命，降低维护成本）,32,Corrugation 波磨,Defects of Corrugation 波磨危害Wesentliche Ursache des Lrms 产生噪音Folgeschden am Fahrweg und Fahrzeugen 对线路和车体造成伤害HSG can remove the corrugat
37、ion effectively 高速打磨可以有效去除波磨,Core technology advantages of HSG-cityCorrugation Removal城铁高速打磨的核心技术优势去除波磨提高轨面纵向平顺性,33,Corrugation removal in several passes 经过几次打磨作业后去除波磨,Grinding Results(Corrugation and Head Check removal etc.)打磨结果（首先去除波峰，逐步接触到波谷）,34,Head Check has been removed 打磨后基本看不出鱼鳞纹痕迹,Before gr
38、inding 打磨前（鱼鳞纹引起的轨面掉块）,After grinding 打磨后,Grinding result of Head Check 鱼鳞纹打磨后的效果,Grinding Results(Corrugation and Head Check removal etc.)打磨结果（伤损去除）,Preventive grinding approach 精细的预防性打磨High working speeds(up to 60 km/h);no possession time required 作业速度快（可达60km/h），可灵活调度Reduces/stops corrugation and rolling contact fatigue 减少波磨和去除因滚动接触产生的疲劳层Tunnel compatible(no cleaning)适用于隧道，作业环保（打磨后无需额外清洁）,35,HSG-city,In a nutshell 福斯罗城铁打磨车的优势,36,We are looking forward to work with you.,While you run your business,we care for your rails！让专业的钢轨维护为您的事业保驾护航！,
