Design of High-Speed Railway Turnouts

Description

High-speed turnouts, a key technology for high-speed railways, have a great influence on the safe and stable running of high-speed trains. Design of High-Speed Railway Turnouts: Theory and Applications, comprehensively introduces the technical characteristics and requirements of high-speed turnouts, including design theories and methods of turnout layout geometry, wheel and rail relations, track stiffness, welded turnout, turnout conversion, turnout components, and manufacture and laying technologies of turnouts.

Analyzing the operational problems of China’s high-speed turnout in particular, this book discusses the control of structure irregularity, state irregularity, geometrical irregularity and dynamic irregularity during the design, manufacture, laying, and maintenance of turnouts. At the end of this reference book, the author provides high-speed turnouts management methods, maintenance standards, testing and monitoring technology, and maintenance technology. Design of High-Speed Railway Turnouts: Theory and Applications will enable railway technicians all over the world to develop an in-depth knowledge of the design, manufacture, laying, and maintenance technology of high-speed turnouts.

The first book in the world to focus explicitly on high-speed turnouts, including design, construction, maintenance and management of high speed turnouts
Expounds the theory of vehicle-turnout system coupling dynamics in detail, aligning this with several examples of computation, and examines the results of dynamic experiments which validate the theory
Written by Ping Wang, who is recognized as a leading researcher and main developer of high-speed turnouts in China

Front Cover 2
Design of High-Speed Railway Turnouts 5
Copyright Page 6
Contents 7
Preface 15
1 Types and Structure 19
- 1.1 Main Types [3] 19
  - 1.1.1 Composition 19
  - 1.1.2 Classification 19
- 1.2 Technical Requirements 20
  - 1.2.1 Excellent Technical Performance 21
  - 1.2.3 Outstanding Adaptability 22
  - 1.2.2 High Cost-Effectiveness 22
- 1.3 Technical Features [6] 22
  - 1.3.1 System Integration 22

Front Cover 2
Design of High-Speed Railway Turnouts 5
Copyright Page 6
Contents 7
Preface 15
1 Types and Structure 19
- 1.1 Main Types [3] 19
  - 1.1.1 Composition 19
  - 1.1.2 Classification 19
- 1.2 Technical Requirements 20
  - 1.2.1 Excellent Technical Performance 21
  - 1.2.3 Outstanding Adaptability 22
  - 1.2.2 High Cost-Effectiveness 22
- 1.3 Technical Features [6] 22
  - 1.3.1 System Integration 22
  - 1.3.4 Scientific Maintenance and Management 23
  - 1.3.2 Theoretical Basis and Practical Tests 23
  - 1.3.3 State-of-the-Art Manufacture and Laying Processes 23
- 1.4 Global Overview of High-Speed Turnouts 23
  - 1.4.1 France 23
  - 1.4.2 Germany 33
  - 1.4.3 China 41
  - 1.4.4 Other Countries 50
- 2 Layout Design 55
  - 2.1 Design Conditions 55
    - 2.1.1 Operation 56
    - 2.1.2 Rolling Stock 56
    - 2.1.3 Tracks [19] 57
    - 2.1.4 Laying 61
  - 2.2 Plane Line Types 62
    - 2.2.1 Design Requirements 63
    - 2.2.2 Transition Lead Curves 65
    - 2.2.3 Switch Rails 69
    - 2.2.4 Clearances [29] 72
    - 2.2.5 Geometric Sizes 76
  - 2.3 Design of Parameters 82
    - 2.3.1 Method Based on Particle Motion 82
    - 2.3.2 Method Based on Rigid Body Motion 85
      - 2.3.2.1 Application cases 85
    - 2.3.3 Design Software [30] 86
  - 2.4 Assessment Methods Based on Wheel–Rail System Vibration [30,31] 87
    - 2.4.1 Theory of Wheel–Rail System Dynamics 87
    - 2.4.2 Multi-Rigid-Body Dynamics Analysis Software 89
    - 2.4.3 Application Cases 91
  - 3 Structural Selection and Rail Design 95
    - 3.2 Overall Structure Selection 95
      - 3.2.1 Guiding-Rail Turnouts 95
      - 3.2.3 Flexible Point Rail 96
      - 3.2.2 Swing Nose Crossing 96
      - 3.2.4 Long Wing Rails 97
      - 3.2.5 Assembled Point Rails 98
      - 3.2.6 Rolled Special Section Wing Rails 99
      - 3.2.7 AT Rail Hot-Forged Heel Ends of Switch Rails and Point Rails 100
      - 3.2.8 Check Rail Made of Grooved Rail 101
    - 3.1 Selection Principles [32] 95
    - 3.3 Design of Rail Members 102
      - 3.3.1 Selection of AT Rail [35] 102
      - 3.3.2 Design of Components at the First Traction Point on Swing Nose Rail 106
    - 3.4 Technical Requirements for Rails [36] 108
      - 3.4.1 Requirements 110
      - 3.4.2 Type, Section, and Length of Rails 111
    - 3.5 Manufacturing of Rails 112
      - 3.5.1 Refining 112
      - 3.5.4 Centralized Detection 113
      - 3.5.2 Finishing 113
      - 3.5.3 Conditioning 113
      - 3.5.5 Long Rail Production 114
    - 4 Wheel–Rail Relation Design 115
      - 4.1 Wheel–Rail Contact Geometry Relation 115
        
        4.1.1 Calculation Methods [39,40] 115
        
        4.1.2 Rail Profiles 116
        
        4.1.3 Wheel–Rail Contact Geometry (Without Wheelset Lateral Displacement) 118
        
        4.1.5 Wheel–Rail Contact Geometry (with Wheelset Lateral Displacement) 127
        
        4.1.4 Wheel–Rail Contact Geometry in the Diverging Line 127
        
        4.1.6 Longitudinal Change Along the Turnout (with Wheelset Lateral Displacement) 131
      - 4.2 Wheel–Rail Rolling Contact Theories in Turnout Zone [42] 134
        
        4.2.1 Hertzian Theory 135
        
        4.2.2 Non-Hertzian Rolling Contact Theories 140
        
        4.2.3 Wheel–Rail Rolling Contact in Turnout Area [42] 149
        
        4.2.4 Calculation Method for 3D Elastic Body Semi-Hertzian Rolling Contact of the Wheel–Rail System in Turnout Area 155
      - 4.3 Assessment of Simplified Models [55] 156
        
        4.3.1 Vertical Irregularities 156
        
        4.3.2 Lateral Irregularities 158
        
        4.3.3 Application Cases 162
      - 4.4 Dynamic Evaluation Based on Wheel–Rail Dynamics in Turnout Area [56] 164
        
        4.4.1 Dynamics Models of Train-Turnout System 164
        
        4.4.2 Vibration Equation of Train-Turnout System 167
        
        4.4.3 Evaluation Indicators 172
        
        4.4.4 Simulation Evaluation 175
        
        4.4.5 Evaluation of Wheel–Rail Relation Design 177
      - 5 Track Stiffness Design 181
        
        5.1 Composition [61] 181
        
        5.1.1 Fastening Stiffness 182
        
        5.1.2 Sub-Rail Foundation Stiffness 183
        
        5.1.3 Track Integral Stiffness 185
        
        5.2 Track Stiffness Design [64–67] 187
        
        5.2.1 Structure of a Fastening for High-Speed Turnouts in China 188
        
        5.2.2 Vertical Stiffness of Rail Pad 189
        
        5.3 Distribution Rules of Track Integral Stiffness 196
        
        5.3.2 Calculation Models 196
        
        5.3.1 Influential Factors 196
        
        5.3.3 Distribution Rule in Ballasted Turnout 198
        
        5.3.4 Distribution Rule in Ballastless Turnout 200
        
        5.4 Homogenization Design for Track Stiffness in a Turnout [71] 200
        
        5.4.1 Dynamic Analysis at Track Stiffness Transition 200
        
        5.4.2 Relation Between Variation Rate of Rail Deflection and Length of Track Stiffness Transition [72–73] 201
        
        5.4.3 Homogenization Design of Track Stiffness in a Turnout 203
        
        5.4.4 Design of Plate Pad 206
        
        5.5 Design of Track Stiffness Transition for a Turnout 207
      - 6 Structural Design of CWR Turnouts 209
        
        6.1 Structural Features 209
        
        6.1.1 Basic Requirements 209
        
        6.1.2 Transmission Path of Temperature Force [75] 210
        
        6.1.3 Force Transmission Structure 211
        
        6.2 Calculation Theories and Approaches 213
        
        6.2.1 Equivalent Resistance Coefficient Method 213
        
        6.2.2 Double-Rail Interaction Method 215
        
        6.2.3 Generalized Variational Method 215
        
        6.2.4 Finite Element Method [78,79] 216
        
        6.3 Regularity of Stress and Deformation of CWR Turnout 220
        
        6.3.1 Distribution Regularity 220
        
        6.3.2 Influential Factors 222
        
        6.4 Design and Verification 228
        
        6.4.1 Contents 228
        
        6.4.2 Design of Rail Laying Temperature of CWR Turnout 230
        
        6.4.3 Arrangement of Creep Observation Stakes 230
        
        6.4.4 Welding Sequence for Large Number Turnout 232
        
        6.4.5 Layout Principle for Turnout Group 233
        
        6.4.6 Layout Principle for CWR Turnout in Tunnel 233
        
        6.4.7 Layout Principle for CWR Turnout on Bridge 234
        
        7 Design of CWR Turnout on Bridge 235
        
        7.1 Regularity of Longitudinal Interaction of CWR Turnout on Bridge 235
        
        7.1.1 Turnout–Bridge–(Slab)-Pier Integrated Model 235
        
        7.1.2 Regularity of Longitudinal Interaction Between Simply Supported Beam Bridge with Ballast Track and Turnout [87] 238
        
        7.1.3 Regularity of Longitudinal Interaction Between Turnout and Continuous Beam Bridge for Ballast Track 243
        
        7.1.4 Regularity of Longitudinal Interaction Between Continuous Beam Bridge with Ballastless Track and Turnout 249
        
        7.2 Dynamic Characteristics of Vehicle–Turnout–Bridge Coupled System [91] 256
        
        7.2.1 Regularity of Dynamic Interaction of Crossover Turnout on Uniform Continuous Beam Bridge [91] 257
        
        7.2.2 Regularity of Dynamic Interaction of Single Turnout on Nonuniform Continuous Beam 262
        
        7.3 Design Requirements of CWR Turnout on Bridge 265
        
        7.3.1 Layout of Turnout and Bridge 265
        
        7.3.2 Design Requirements for CWR Turnout on Bridge 267
        
        8 Conversion Design of High-Speed Turnouts 271
        
        8.1 Conversion Structure and Principle 271
        
        8.1.1 Conversion Structure [105] 271
        
        8.1.2 Principle of Turnout Conversion [106] 275
        
        8.2 Calculation Theory of Turnout Conversion [106] 277
        
        8.2.1 Calculation Model [107,108] 278
        
        8.2.2 One-Machine Multi-Point Traction Mode [110] 281
        
        8.2.3 Test of Friction Coefficient of Slide Plate 282
        
        8.3 Study and Design of High-Speed Turnout Conversion 282
        
        8.3.1 Switch Rail of High-Speed Turnout 282
        
        8.3.2 Point Rail of High-Speed Turnout 288
        
        9 Design of Rail Substructure and Components 293
        
        9.1 Rail Substructure 293
        
        9.1.1 Tie of Ballast Turnout 294
        
        9.1.2 Embedded Long Tie for Ballastless Track [120] 298
        
        9.1.3 Slabs for Ballastless Turnout 306
        
        9.2 Plates of Turnout 310
        
        9.2.1 Forces on Plates [121] 311
        
        9.2.2 Check Rail Plate [122,123] 311
        
        9.2.3 Common Plates 312
        
        9.2.4 Elastic Fastening and Antifriction Elastic Clips of Slide plate at Switch 314
        
        9.3 Components of Turnout Fastenings 317
        
        10 Theoretical Validation of High-Speed Turnout Design 323
        
        10.1 Validation of Turnout Dynamic Simulation Theory 323
        
        10.1.1 Comparison of Dynamic Responses [126–128] 323
        
        10.1.2 Comparison of Wheel-Load Transition 325
        
        10.1.3 Comparison of Wheelset Lateral Displacement [129] 325
        
        10.1.4 Test on Lateral Force of Check Rail 327
        
        10.2 Validation of Analysis Theory of Longitudinal Interaction of CWR Turnout on Bridge 327
        
        10.2.1 Model of CWR Turnout on Bridge [130,131] 327
        
        10.2.2 Field Test on CWR Turnout on Bridge [134] 329
        
        10.3 Validation of Analysis Theory of Vehicle–Turnout–Bridge Dynamic Interaction 334
        
        10.4 Validation of High-Speed Turnout Conversion 336
        
        10.4.1 Field Test in Qingdao–Ji’nan Line [137] 336
        
        10.4.2 Laboratory Test of Conversion of Switch Rail of No. 42 Turnout [138] 337
        
        10.4.3 Conversion Test on Point Rail with Double Flexible Rails of No. 42 Turnout 339
        
        11 Manufacturing Technologies of High-Speed Turnouts 343
        
        11.1 Manufacturing Equipment and Processes 343
        
        11.1.1 Providers of High-Speed Turnouts in China 343
        
        11.1.2 Major Process Equipment 343
        
        11.1.3 Manufacturing Processes 345
        
        11.2 Key Processes for Rails 345
        
        11.2.1 Process Flow and Main Control Points 345
        
        11.2.2 Forging of Heel of 60D40 Rail and Quality Control [140,141] 346
        
        11.2.3 Heat Treatment and Quality Control [143] 351
        
        11.2.4 Control of Line Type in Milling the Switch Rail [147,148] 356
        
        11.3 Key Processes for High-Speed Turnout Plates 357
        
        11.4 Assembly and Acceptance 359
        
        11.4.1 Assembly Process of Critical Turnout Parts 359
        
        11.4.2 Integral Assembly 361
        
        11.4.3 Acceptance after Assembly 362
        
        11.4.4 System Integration 363
        
        12 Laying Technology 365
        
        12.1 Transport [150] 365
        
        12.1.1 Modes of Delivery 365
        
        12.1.2 Hoisting and Storage 367
        
        12.2 Laying of Ballast Turnout 367
        
        12.2.1 In-situ Assembly and Laying 368
        
        12.2.2 Ex-situ Assembly and Laying 372
        
        12.2.3 Control Measures for Laying Quality [153] 373
        
        12.3 Laying of Ballastless Turnout 374
        
        12.3.1 In-situ Laying of Ballastless Turnout with Embedded Ties: Construction Process and Key Technologies 374
        
        12.3.2 Ex-situ Laying of Ballastless Turnout with Embedded Ties 375
        
        12.3.3 Laying of Ballastless Slab Turnout: Construction Process and Key Technologies 375
        
        12.3.4 Control Measures for Laying Quality of Ballastless Turnout 379
        
        12.4 Accurate Adjustment Technology 380
        
        12.4.1 Detection Technologies of Turnout Static Geometry 380
        
        12.4.2 Assessment Standard for Turnout Static Geometry 383
        
        12.4.3 Basic Requirements 385
        
        12.4.4 Analysis Software [162,163] 386
        
        12.5 Dynamic Detection and Acceptance of High-Speed Turnout 386
        
        13 Irregularity Control of High-Speed Turnouts in Operation 391
        
        13.1 Structural Irregularity Induced by Poor Wheel–Rail Relation 391
        
        13.2 Geometric Irregularity 396
        
        13.3 Status Irregularity 405
        
        13.3.1 Field Survey 405
        
        13.3.2 Dynamic Simulation Analysis 407
        
        14 Maintenance and Management 415
        
        14.1 Management Policies and Maintenance Standards 415
        
        14.1.1 Type of Maintenance Work 415
        
        14.1.2 Management Organization 416
        
        14.1.3 Mode of Maintenance 416
        
        14.1.4 Maintenance Standard 417
        
        14.1.5 Evaluation of Turnout Quality 419
        
        14.2 Inspection and Monitoring Technologies for High-Speed Turnouts 424
        
        14.2.1 Inspection of Turnout Status and Geometry 424
        
        14.2.2 Inspection of Turnout Rails 430
        
        14.2.3 Turnout Monitoring System 432
        
        14.3 Maintenance Technologies 434
        
        14.3.1 Rail Grinding [180,181] 434
        
        14.3.2 Maintenance of Ballasted Turnout 441
        
        14.3.3 Improvement of the Settlement of Ballastless Track Foundation in the Turnout Area 444
        
        14.4 Management of High-Speed Turnouts 450
        
        14.4.1 Permanent Way Management Information System 450
        
        14.4.2 Digital Management of Engineering Equipment 451
        
        14.4.3 RAMS Management of High-Speed Turnouts 452
        
        References 461
        
        Index 469

Author's affiliation

Ping Wang: Doctoral supervisor and professor of civil en

Theory and Applications

Description

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