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1、High Speed Maintenance for Rails 城市轨道交通钢轨的高速维护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 1High 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 cor
2、e technology advantages of HSG 福斯罗公司及高速打磨技术的核心优势 + + + +2High 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 mainten
3、ance 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 福斯罗公司及高速打磨技术的核心优势+ + +- -3Influence Factors of the wheel/rail relationship in UTS Influence Factors of the wheel/rail relationship in U
4、TS 城市轨道交通中影响轮轨关系的因素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4High 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
5、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 福斯罗公司及在高速
6、打磨技术的核心优势 + + +- -5Problems and challenges of rail maintenanceProblems and challenges of rail maintenance钢轨维护遇到的问题和挑战钢轨维护遇到的问题和挑战 Line mileage 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
7、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短 Less maintenance time (3-4 hours) 维护天窗少（3-4小时） 6Corrugation Corrugation 波磨波磨（北京地铁（北京地铁6 6号线）号线）Head checks Head checks 疲劳裂纹疲劳裂纹（鱼鳞纹）（鱼鳞纹）Problems and challe
8、nges of rail maintenance Problems and challenges of rail maintenance 钢轨维护遇到的问题和挑战钢轨维护遇到的问题和挑战 Common Railway Problems Common Railway Problems 常见的钢轨问题常见的钢轨问题78High 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Influence
9、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 福斯罗公司及在高速打磨技术的核心优势 + + +- -Linie
10、6 gemessen 0,25 mm!波磨深度0.25 mmTraditional 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 Grinding speed Grinding speed 打
11、磨速度打磨速度km/hkm/h35681015Wave length 表面不平顺波长 mm13.823.127.637.046.369.3Existing maintenance methods and effects for rails Existing maintenance methods and effects for rails 现有的钢轨维护手段和现有的钢轨维护手段和效果效果Annealing effect 发蓝带 Facet 刻面Periodic variation 周期性变化Ripple depth 波纹深度9To produce big smock 产生烟尘较大（烟雾和粉尘）
12、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 Existing maintenance methods and effects for rails 现有的钢轨维护手段和效果现有的钢轨维护手段和效果 Cleanliness of existing maintenance methods for rails Cleanliness of ex
13、isting maintenance methods for rails 现有的钢轨维护手段的清洁现有的钢轨维护手段的清洁性性1011High 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
14、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 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+ + +- -12Picture size 4,2 X 7,1
15、 cmPicture size 4,2 X 7,1 cmPicture size 4,2 X 7,1 cmPicture size 4,2 X 7,1 cmPicture size 4,2 X 7,1 cmPicture size 4,2 X 7,1 cmCorrugation and slip waves Corrugation and slip waves increase noise and vibrations. The comfort of travellers and neighbours decreases, on the other hand increasing dynami
16、c 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。Rolling contact fatigue Rolling contact fatigue is a material transformation. A hardened surface layer develops and leads to surface cracks (head checks and squats). The ultima
17、te 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 Rail pollution and rust corrupt the rail/wheel contact. Irregularities in traction 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
18、 defects and necessity for rail preventiveRail defects and necessity for rail preventive grinding grinding 钢轨病害和钢轨预防钢轨病害和钢轨预防性打磨的必要性性打磨的必要性Rail defects Rail defects 钢轨病害钢轨病害波磨波磨鱼鳞纹鱼鳞纹表面附着物表面附着物Rail defect: Headcheck 钢轨病害：鱼鳞纹Defect development 钢轨病害的发展过程1314The Magic Wear Rate神奇的钢轨磨损率The development o
19、f 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based on: J. Kalousek, E. Mage
20、l: The magic wear rate. Railway Track & Structure, March 1997, pp.50 - 52.Defect depthDefect depth伤损深度伤损深度New railNew rail新钢轨新钢轨Accumulated traffic (MGT)Accumulated traffic (MGT)累计通过量累计通过量No grindingNo grinding无打磨无打磨Common preventive grindingCommon preventive grinding常见预防性打磨常见预防性打磨Corrective mainten
21、anceCorrective maintenance修正性打磨修正性打磨HSG preventive grindingHSG preventive grinding预防性钢轨打磨预防性钢轨打磨Rail defects and necessity for rail preventive grinding Rail defects and necessity for rail preventive grinding 钢轨病害和钢轨钢轨病害和钢轨预防性打磨的经济效益预防性打磨的经济效益Necessity for rail preventive grinding Necessity for rail
22、preventive grinding 钢轨预防性打磨的经济效益钢轨预防性打磨的经济效益Need HSG preventive grinding需要HSG预防性打磨15High 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 preven
23、tive 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 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
24、+ + +- -High speed grinding High speed grinding 高速打磨高速打磨 16work speed作业速度HSG-2: 80km/h80km/h HSG-City: 60km/h60km/hscope of grinding between打磨范围: +45- -70+45- -70amount of once grinding单次打磨量: 0.01-0.02mm0.01-0.02mmrail surface roughness after grinding打磨后轨面粗糙度：8 mdust recovery over 90%, dont need to
25、clean the track灰尘回收率：90%90%以上以上, 无需清洗道床 noise emissions 作业噪音排放：作业噪音排放：65-85db65-85dblow production cost 生产成本低 （无动力）no need to remove the signal device无需拆卸线路信号装置,如计轴器计轴器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
26、不同牵引车：轨道车、公铁两用车）HSG-2 HSG-2 高速打磨车高速打磨车 & HSG-City & HSG-City 城铁高速打磨车城铁高速打磨车High speed grinding High speed grinding 高速打磨高速打磨 1718High 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
27、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 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 te
28、chnology advantages of HSG 福斯罗公司及在高速打磨技术的核心优势+ + +- -1-10,000 trains10,000-20,000 trains20,001-35,000 trains35,001-50,000 trains50,001-75,000 trains75,001-100,000 trainsMore than 100,00 trainsCommercial operations in Germany since 2008since 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 Germa
29、ny 在德国应用高速打磨技术进行打磨作业 Most 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 Promote of HSG in Germany and worldwide refer
30、ences of HSG-city (without China) China) 高速打磨在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 Promote of HSG in Germany 高速打磨在德国的推广高速打磨在德国的推广1920 from 2008 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
31、references of HSG-city (without Promote of HSG in Germany and worldwide references of HSG-city (without China) China) 高速打磨在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 Worldwide references for HSG-City 城铁高速打磨在其他国家的应用城铁高速打磨在其他国家的应用 2015,1-2015,22014,92014,10-2014,112
32、013,5-2013,11京沪线京沪线预防性打磨预防性打磨京沪济南局京沪济南局预防性打磨预防性打磨哈大线哈大线预防性打磨预防性打磨2014,10兰新二线兰新二线优化廓形优化廓形兰新二线兰新二线线路开通前预防性打磨线路开通前预防性打磨2015,1-2015,2References in ChinaReferences in China中国打磨业绩中国打磨业绩HSG-221HSG-City HSG-City References in ChinaReferences in China中国打磨业绩中国打磨业绩Beijing Metro 北京地铁Line 6 6号线 Line 15 15号线Line
33、14 14号线 Changping line 昌平线Line 7 7号线2015 - 201622HSG-City HSG-City References in ChinaReferences in China中国打磨业绩中国打磨业绩Guangzhou Tram 广州有轨电车海珠线（2016.1，3km）Liede Bridge SouthNanfengExhibition West1234Grinding section ExhibitionExhibition Ost23HSG-City HSG-City References in ChinaReferences in China中国打磨
34、业绩中国打磨业绩Harbin Metro 哈尔滨地铁（2015.10，单线35km）2425High 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 sp
35、eed grinding 高速打磨Worldwide 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+ + +- -Passive driven grinding stones 被动驱
36、动砂轮被动驱动砂轮Passive adaptation to rail cross profile 被动适应钢轨横向廓形Optimization 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 磨石工作原理磨石工作原理Introduction of HSG technologyIntroduction of HSG technology高速打磨技术
37、介绍高速打磨技术介绍电机主动驱动砂轮电机主动驱动砂轮26High 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 track preparation, e.g. dismantling of track installations like axle counters 打磨前无须拆除轨道装置无须拆除轨道装置，如：计轴器计轴器No extra work after grinding, e.g. cleaning of insulated rail joints 打磨作业后没有额外的工作，
38、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 consumables from inside of the machine 在打磨车内部更换磨石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 workHigh
39、er flexibility in planning of grinding work 更灵活的安排打磨计划。更灵活的安排打磨计划。Less traffic disruption and more effective use of track possessionLess 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更少干扰正常运营与更高的打磨效率Characteristics of HSG Characteristics of HSG 高速打磨特点高速打磨特点Introductio
40、n of HSG technologyIntroduction of HSG technology高速打磨技术介绍高速打磨技术介绍27Grinding 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Before grinding8 days after6 month afterTSI limitWave lengthWave lengthRail Roughness LevelRail Roughness L
41、evelAcoustic grinding in Austria 澳大利亚的降噪打磨降噪打磨Introduction of HSG technology高速打磨技术介绍高速打磨技术介绍2829High 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 fo
42、r 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 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
43、磨技术的核心优势+ + +- -Technical Data 技术参数Working speed 25 - 60 km/h 工作速度25-60km/h2 Magazines, 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 nonst
44、op 40km无中断打磨Technical data of HSG-CityTechnical data of HSG-City高速打磨的技术数据高速打磨的技术数据30Core technology advantages of HSG-city-PreventionCore technology advantages of HSG-city-Prevention城铁高速打磨的核心技术优势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长钢轨使用寿命mainly for preventive grinding (lower main
45、tenance 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）31Corrugation Corrugation 波磨波磨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 corrugation effectively 高速打磨可以有效去除波磨Wellenlnge 波长Wellentiefe 波深(Amplitude)Core technology a
46、dvantages of HSG-cityCorrugation RemovalCore technology advantages of HSG-cityCorrugation Removal城铁高速打磨的核心技术优势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去除波磨提高轨面纵向平顺性322134Corrugation 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. ) Grinding Results ( Corrugation an
47、d Head Check removal etc. ) 打磨结果（首先去除波峰，逐步接触到波谷）打磨结果（首先去除波峰，逐步接触到波谷）33Head Check has been removed 打磨后基本看不出鱼鳞纹痕迹 Before grinding 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. ) Grinding Results ( Corrugation and He
48、ad Check removal etc. ) 打磨结果（伤损去除）打磨结果（伤损去除）34Preventive 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）HSG-cityIn a nutshell 福斯罗城铁打磨车的优势 35We are looking forward to work with you.While you run your business, we care for your railsWhile 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！让专业的钢轨维护为您的事业保驾护航！36
