道岔的焊接

How to do

Welding in TO 如何在岔区进行焊接

Preample SkV welding

Before welding and flame cutting is started, ascertain minimum tensile strength and quality of rails from the rolling identification marks which are as follows (according to UIC-Code 860):

在钢轨焊接和切割前,先介绍下根据钢轨的最小抗拉强度定义的钢轨分级。（根据UIC-Code 860)

Rolling mark （轧制标记）Grade 700

Rolling mark Grade 900 A

Rolling mark Grade 900 B

Rolling mark Grade 1100

Rolling mark HH H ead H ardened Grade 硬头轨级

When welding head hardened rails, the SkV procedure should be applied due to the narrow heat-affected zones.

在进行硬头轨焊接的时候，SKV的步骤必须适用于狭窄的热影响区域。

When welding at temperatures below 0 °C (+ 32 °F), preheat both rail ends to a hand warm temperature over a distance of 1.0 to 2.0 m. Keep luting sand plastic by warming up.

当焊接时，外界温度低于0 °C (+ 32 °F), 对焊缝两侧至少1.0 到 2.0 m钢轨进行预加热。在用封箱沙封沙型时，也要进行预加热。

Do not weld ends with damaged or burnt fish bolt holes. To avoid damage, use THERMOR for filling the first fish bolt holes on each side of the joint.

不要焊接时，对弹性基板造成破坏。

Before welding remove tar and oil residues, if any.

在焊接前要对两侧的油迹进行清理。

Set the welding procedure as indicated in the ”Data Sheet by ET”

焊接的过程应在施密特的技术资料上有所显示。

Loosen the rail fasteners on at least three ties each on both sides of the joint.

At the last ties put the rail pad out before welding

The crown is arranged with wedges and a 1 m-straight edge according to the data sheet. Do not remove wedges before the weld has fully cooled down.

用楔块和1米的直规尺按照数据表的内容进行设置。在焊接完全冷却前不要移走楔块。

Check the height (crown) after the weld is finished and has cooled down.

在焊接完成和冷却之后检查高度。

The gauge side of the rail head is aligned with wedges, using the 1 m-straight edge for control.

用楔块进行轨头的对准，用1m的直规尺进行控制。

Always carry out closure welds at the stress-free condition of the rail. Check rail temperature by means of magnetic rail thermometer. Find out the difference between actual rail length and length of rail at stress-free condition from table on page 22. Loosen rail fasteners and produce stress-free condition of rail (using rail hammer).

通常应该在钢轨应力释放的情况下进行焊接。用磁性轨温计测量轨温。在后页的表中找出实际钢轨长度和应力释放的条件下的钢轨长度的不同。松动紧固件达到钢轨应力释放的条件（利用钢轨锤）

By heating the rails on one or both sides of the joint gap, using the rail heating device.

用钢轨加热设备加热接头空隙一边或两边。

Retighten rail fasteners, except for the fasteners on those tie-fields that have to be left free for welding. Mark a check-line (using a copper or brass scribe-needle) at right angle to the rail, via rail foot and base plate on the first sleeper adjacent to the joint gap.

再拧紧钢轨扣件，除了因焊接需要松开的扣件之外。在相邻岔枕上的轨脚及弹性基板上与钢轨成正确的角度上标记检查线（用铜或者黄铜的划线针）。

During execution of the weld watch the check-line and correct hydraulic rail puller and heat supply to the rail, if necessary, in order to maintain stress-free condition of the rail.

在焊接施工的过程中，如果有需要，需要观察检查线和纠正液压轨道拔出机以及供给轨道的加热，这都是为了保持钢轨的应力释放状态。

Never let tension stress (backward creeping of the rail!) occur in the weld, unless it has cooled down to approx. 500 °C.

除非冷却到大约500°C，不能让拉伸应力（钢轨的反向变形）出现在焊接过程中。

Variation of rail length for producting stress-free condition （在应力释放的条件（在应力释放的条件下钢轨长度的变化）下钢轨长度的变化）

Temperatur e （温度） Rail length (m) （钢轨长度）

Difference （不同） ? t (C °)

30

60

90

120

150

180

1 0,4 0,7 1,0 1,4 1,7 2,1

2 0,7 1,4 2,1 2,8 3,5 4,1

3 1,0 2,1 3,1 4,1 5,2 6,2

4 1,4 2,8 4,1 5,

5 6,9 8,3 5 1,7 3,5 5,2 6,9 8,

6 10,4 6 2,1 4,1 6,2 8,3 10,4 12,4

7 2,4 4,

8 7,3 9,7 12,1 14,5 8 2,8 5,5 8,3 11,0 13,8 16,6

9 3,1 6,2 9,3 12,4 15,5 18,6 10 3,5 6,9 10,4 13,9 17,3 20,7 11 3,8 7,6 11,4 15,2 19,0 22,8 12 4,1 8,3 12,4 16,6 20,7 24,8 13 4,5 9,0 13,5 17,9 22,4 26,9 14 4,8 9,7 14,5 19,3 24,2 29,0 15 5,2 10,4 15,5 20,7 25,9 31,3 16 5,5 11,0 16,6 22,1 27,6 33,1 17 5,9 11,8 17,6 23,5 29,3 35,2 18 6,2 12,4 18,6 24,8 31,1 37,3 19 6,6 13,1 19,7 26,2 32,8 39,3 20 6,9 13,8 20,7 27,6 34,5 41,4 21 7,3 14,5 21,7 29,0 36,2 43,5 22 7,6 15,2 22,8 30,4 38,0 45,5 23 7,9 15,9 23,8 31,7 39,7 47,6 24 8,3 16,8 24,8 33,1 41,4 49,7 25

8,6 17,3 25,9 34,5 43,1 51,8

l = ? t * L * 0,0115

Example: Rail length: L = 120 m Stress-free temperature: = 20 °C Actual temperature: = 6 °C Temperature difference: ? t = 14 °C Necessary alteration of rail length: l = 19,3 mm

例如：钢轨长度： L= 120 m 应力释放温度： = 20 °C 实际温度： = 6 °C

温差： ? t = 14 °C

需要调整的钢轨长度： l = 19,3 mm

焊接）

关于尖轨焊接）Particulars for the welding in switches（关于尖轨

Switches may only be welded when they are properly aligned, in height and direction, and also the paperwork is right.

尖轨部分的焊接必须在正确对准，高程和方向正确以及书面工作都做好的条件下进行。

Check the rectangular position of the interlocking devices.

检查联锁装置的垂直位置。

When adjusting the interlocking devices always inform the signalling staff.

在调整联锁装置的时候必须告知信号员。

Weld the joint, starting from the crossing (frog). Complete welding at the start and finish of the switch after neutralizing as these are closure welds. Note special regulations given by railway authorities.

应该从辙叉区域开始焊接。由铁路当局权威人士给与规定注释。

Joints at the tongues (switchblades) may only be welded after all other welds are made and shrinkage has finished.

在转辙机开关的接头，只能在其他所有的焊接和钢轨的变形完成后进行焊接。

The shrinkage rate of the weld (2 mm) has to be considered.

必须考虑焊接的收缩率（2mm）。

Execute welds in switches - except for tongue joints, within a temperature of 3 °C to 25 °C.

尖轨的焊缝除了接头部分，内部温度是3 °C ----- 25 °C。

Execute tongue joints at temperatures between 10 °C and 15 °C.

接头部分温度是：10°C ---15 °C。

By lower temperatures make the rails handwarm with spezial burners.

低温情况下可用加热装置始钢轨升温。

Remove excess metal on the head of the rail with hydraulic rail shear or with hot chisel. Leave the risers on the rail foot. Remove them after complete cooling down of the weld by knocking them towards the rail using a hammer.

用液压钢轨剪或者热轧凿除去轨头多余的金属部分。留下立管在钢轨底部。在焊接冷却完成后用锤子沿着钢轨走向敲击除去焊渣。

When grinding, apply safety goggles and safety guards.

在打磨过程中，使用安全护目镜和相应的防伪措施

Rough grinding（粗磨）

Rough grind the weld without touching the running surface of the rail.

粗磨焊缝没有接触的钢轨行走面。

Final grinding（终磨）

When welds have completely cooled down, grind running surface and sides of the head and control with a 1 m-straight edge.

当焊缝冷却完成之后，打磨行走面和轨头的两端，并且用1m的直规尺进行控制。

running surface: + 0.2 mm; - 0.2 mm

flanks of rail head: + 0.2 mm; - 0.2 mm

行走面：+ 0.2 mm; - 0.2 mm

轨头两侧：+ 0.2 mm; - 0.2 mm

These both variations must be levelled out by grinding over a distance covering 500 times (in tracks with high speed traffic 1000 times) the amount of deviations on both sides.

该精度需要通过在500倍（高速线为1000倍）的偏差范围内打磨来调平。

Final finish（最后完成）

Carefully remove all sand and cast metal residues from the welds, using a blunt chisel. Avoid notches. Before leaving the welding site, complete the treatment necessary to the permanent way. Fitting the intermediate plates, tightening of fastenings, replacing ballast, tamping of sleepers, etc.

用钝凿仔细清除焊缝里所有沙土和金属残留物。避免切口。在离开焊接现场之前，一些永久性的必要工作我们需要去做。例如填充中间板，拧紧扣件，道蹅替换，夯实轨枕等等。

Particulars for the welding of rails of UIC grade 900 A and 900 B （关于UIC中等级900A和900B的钢轨焊接）If the rail joint is not to be welded immediately after flame cutting, the whole rail profile over a length of 0.10 m (4“) should be uniformly preheated to a minimum of 400 °C (750 °F).

如果钢轨在切割后不能立即焊接，整个钢轨轮廓（超过0.1m的长度）必须均匀的预热到最低400 °C

If possible, avoid welding at temperatures below - 3 °C. In case of emergency heat the rail ends to approx. 50 °C (120 °C) before fitting the moulds.

尽可能的不要在低于- 3 °C的时候进行焊接。紧急情况下在模具拟合之前加热钢轨的两端到大约50 °C。

Particulars for the welding of head hardened rails

）

关于硬头轨的焊接）

（关于硬头轨的焊接

The analysis for head hardened rails corresponds to that of grade 900 A.

硬头轨对应于强度为900 A。

A reduced cooling rate, as is necessary when welding rails of grade 1100 or

higher, is not allowed to be applied with head-hardened rails.

为了降低冷却速率，在必要时焊轨应使用1100等级或者更高的，不允许用于硬头轨。

When welding head hardened rails to rails with lower tensile strength, use portion applicable for the rail with the lower tensile strength.

当在低抗拉强度时焊接硬头轨和钢轨的时候，利用适用于低抗拉强度的钢轨。

Start procedure welding in TO

开始道岔的焊接

1. Step

free welds in the TO

第一步：

Get approval for starting welding in turnouts

得到审批可以在道岔内进行焊接

1. Before starting welding procedure, make a handover after quality control and correction works.

在开始焊接程序前，完成相关调节工作及质量控制后执行交接程序。

2. Check turnout before welding begins

开始焊接前检查道岔

2.1 before starting the welding, check all the punch marks with an angle at the

stock rail joint, heel joint and set of switches

开始焊接前，用方尺检查基本轨和尖轨等所有控制点

2.2 if necessary adjust before welding

如果有必要，要在焊接前进行调整。

By lower temperature heat the rail in the TO handwarm before to measure and control !!!

如果外界温度较低，要在测量和切割前，先对钢轨进行预加热。

Check also the insulation joints in TO before welding

Normal 30-50mm distance by angular impackt (100mm exceptional case for a special system !!! )

在焊接前也要检查道岔轨的绝缘节

一般情况下通过方尺测量的间距是30-50mm （100mm 是用于特殊的系统）

3. Welding gap 焊缝的宽度

Set the welding gap as indicated in the ”Data Sheet by ET”. 根据史密特的操作说明，设好焊缝的宽度

Cut the rail with a special cutting devise, in one line exact straightly 使用专用切割设备切割钢轨，保证平直。

By lower temperature heat the rail in the TO handwarm before to measure and cutting !!!

在外在外界气温很低的情况下，要在测量和切割前，先对钢轨进行预加热。界气温很低的情况下，要在测量和切割前，先对钢轨进行预加热。

Cutting position is shown with

切割位置

4. Welding in TO 道岔焊接

Start 6-10 free welds before distressing 在放散前，可以先进行6或10个接头的焊接To complete the first 6-10 welds inside turnout in conformity of turnout types

(long or short section rails)

道岔中间的焊缝根据道岔的类型分为6个（小号码道岔）或10个（大号码道

岔）。

6 welds for short section rails

6个接头的焊接（小号码道岔）

10 welds for long section rail 10个接头的焊接（大号码道岔）

Attention: Move the frog nose to the middle with a crank handle before welding at the

注意：在焊接心轨段时，要在焊接前，用摇把转动辙叉到中间位置。

frog

nose

Comment: the welding number and welding sequence can be found in the protocol

意见：可以在焊接检查表上找到焊接的数量和顺序

make a welding protocol for each weld with details: 每一次焊接要详细填写焊接检查表number, name, date, TO, station……. 包括焊接数量，顺序，日期。车站

also a grinding protocol

打磨也要有相应的检查表

for each weld !!!

每一次焊接

Comment to Twistpoint’s对变坡点的意见

Take care of the twist joints during the welding of switch rails and frog rails!

要注意在尖轨区和心轨区的变坡点焊接。

Twisted joint()

Align the rail vertex and running edge. Ignore the misalignment of the foot.

joint

Twist joint 变坡点

Align the rail vertex and the running edge. Ignore the misalignment of the foot.

对齐钢轨的受力侧和轨顶，忽略轨底的不平。

2. Step

Distress weld in TO

第二步：道岔焊接前的消应处理

Destressing

消应处理

How to compensate the rail length variation caused by the temperature change? The rail has no gap and is fastened to the sleeper every 60cm. That’s why the rail cannot move. As the physical and thermal character of steel tends to change the length, positive or negative tension takes place along with the shrinkage in winter time and expansion in summer time. We must find the neutral temperature, which usually is the average temperature of a year, so that the tension and pressure in the summer and winter time will not be too high to damage the track. The system can only work if the sleepers are fastened to the ground and the track cannot move.

如何补偿由于温度的变化，而产生的钢轨长度的变化？钢轨间没有缝隙，并且每60cm 固定在轨枕上，这样钢轨就不能移动。在冬季和夏季，钢轨会相应的伸缩，这样内部就产生了温度应力。所以我们必须设定一个锁定温度（一般是年平均温度）。这样冬季和夏季产生的温度应力就不会太高。

Destress Welding

Follow all the manufacturer data from ET to prevent welding failure !

按照史密特的操作指示进行关于操作，避免焊接失败

Attention: 注意

Before loosening the fasteners, the rail temperature must be lower than the installation temperature. Otherwise, it can be very dangerous!

在松扣件前，轨温要低于安装时的温度。否则会发生危险。

Comment 意见

A temperature variation of 20 degrees can result in 10cm change in a rail of 400m

long, which means a high pressure or a gap within the rail.

当400m钢轨发生了20度温差变化，就会造成10cm的钢轨长度变化。这就意味着钢轨内部产生了很高的温度应力。

Destressed welding at the two ends of turnout. At the two ends of the TO must 200m rail destressed by flams with a rail heating devise

道岔两端焊接前的放散，要保证对道岔两端200M 的钢轨通过钢轨加热设备，进行消应处理。

Sequence of distressing

放散的顺序

loosening the fasteners 松开扣件

punch the rail with a plastic hammer 用塑料锤冲击钢轨

to measure the rail temperature (stress free temperature) 测量轨温

look for different from destress and stress free temperature = ? t

计算现场温度与锁定轨温的差

to measure the length of the rail 测量轨长

look in the tabulary for elongation 查看钢轨长度变化表

l = ? t * L * 0,0115 计算去放散量

marke the rail elongation on the rail and a sleeper

在钢轨和轨枕上做好放散位置的标记

heat the rail to the marker 加热钢轨，放散到指定位置。

fastening the rail 紧固扣件

- short TO make handwarm by lower temperature

- long TO destress the section rails, and make the TO handwarm by lower temperature

小号码道岔在低温情况下，采用预加热设备对钢轨进行加热。

Commant 意见

Use a crank handle to move the frog nose to the middle before the welding around the frog area begins.

在焊接心轨段时，要在焊接前，用摇把转动辙叉到中间位置。

Comment 意见

Take care of the twist joints during the welding of switch rails and frog rails

要注意在尖轨区和心轨区的变坡点焊接

make a protocol about destressing TO

道岔的放散要建立记录

Align the rail vertex and the running edge. Ignore the misalignment of the foot.

对齐钢轨的受力侧和轨顶，忽略轨底的不平。

Welding at the FAKOP

在FAKOP区的焊接

Rail alignment and Gauge line should be limited to straight edge of rail running edge 轨道的线形和轨距要以轨道的受力边为准。

FAKOP

FAKOP

Rail alignment and GI should be limited to straight edge of running edge it 1,5m straight edge laps the curve

轨道的线形和轨距边要以轨道的受力边为准。测量的直尺大于如果是1,5m会和曲线重合，造成测量不准。

4. Step

welds at the tongue rail

never start welding before distressing !!!

第四步：在尖轨处的焊接要先进行放散

After completing the destressing record, the weldings of tongue rails can start.

After destressing, the stock rail cannot be moved so that the tongue rail can be adjusted to right position with the punchmarks on stock rail.

消应完后，尖轨的焊接就可以开始。消应完后，基本轨就不会位移，这样尖轨

就可以根据基本轨上的控制点调到正确位置。

通过方尺调整尖轨

adjust at the punch marks with attended shrinking gauge: 2mm

通过控制点调整时，要考虑到收缩的2mm

Before welding switch rail welding joint, request supervisor expert to check the alignment of turnout.

在焊接尖轨前，要求监理要检查道岔线型。

Attention: 2mm to shrink the weld if cool down !!!

注意：当焊接接头的温度冷却后，有2mm的收缩。Check the anti creep devise 检查防爬器

Anti-creep device in middle position 防爬器要居中

6. Step

Replacement of failed welds

Before start replacing work, inform supervisor welding and get his approval

第6步：要通知监理，得到监理同意后，才能更换焊接失败的岔轨，