Product Description
The WJ-2 rail fastener system is a ballastless track fastener system developed to meet the technical requirements of passenger dedicated line fastener systems and adapt to the laying of various ballastless tracks. The fastener system consists of T-bolts, nuts, flat washers, spring clips, insulating blocks, iron washers, insulating buffer plates, rail pads, anchor bolts, heavy spring washers, flat washers, and pins positioned on concrete sleepers or rails. When adjusting the track height, use height adjustment pads (rail pads and iron pads).
Technical requirements of WJ-2 rail fastening system
●Rail fasteners are required to lay seamless lines on the bridge. There is a height adjustment pad under the track and under the pad, and the fastener has a gauge adjustment of +10mm to -12mm, and the track height adjustment is +30mm to 0 mm. The longitudinal resistance of each fastener rail is 6.5kN ± 0.5kN. If structural measures are taken, it can be reduced to 3.6kN ± 0.4kN, and the longitudinal resistance of the rail is 7 kN lower than that of ordinary fasteners.●Each set of fasteners has a bending pressure of ≥ 20 kN;
●Each set of fasteners has a longitudinal rail resistance of not less than 10 kN;
●The fastener system should not be damaged after 3 million load cycles, and the gauge should be less than 6 mm;
●Single rail left and right position adjustment: -6 ~ +4 mm, track gauge adjustment: -12 ~ +8 mm; track height adjustment: -4 ~ +16 mm;
●System flexibility: static stiffness of rail pad 50 kN/mm;
●The pull-out force of embedded iron seat is not less than 70 kN.
Parameters
WJ-2 Rail Fastening System Assembly
Item | Drawing No. | Name | QTY | Material | Volume |
1 | Research line 9705(08)-3 | T-Bolt | 2 | 45# | 0.684kg |
2 | GB/T41 | Nut M22 | 2 | 45# | 0.224kg |
3 | TB/T1495.4-92 | Flat washer 22 | 2 | Q235-A | 0.138kg |
4 | Research line 9705(08)-4b | Joint rail clip | 2 | 60Si2MnA | 1.18kg |
5 | Research line 1114-3a | Rail plate | 1 | thermoplastic polyester elastomer | 272cm3 |
| Research line 1114-4b | Rubber plate | | thermoplastic polyester elastomer and Polymer wear-resistant material | 272cm3 |
6 | Research line 1114-3a | Type-I tie plate | 1 | QT450-10 | 11kg |
| Research line 1114-4b | Type-II tie plate | | QT450-10 | 11kg |
7 | Research line 9705(08)-11 | Elastic pad | 2 | thermoplastic polyester elastomer | 405cm3 |
8 | Research line 1114-6 | Insulator | 2 | Fiberglass Polyamide 66 | 93cm3 |
9 | Research line 1114-7 | Anchor bolt | 2 | 45# | 2.14kg |
10 | GB7244 | Heavy-duty spring washer 30 | 2 | 65Mn | 0.05kg |
11 | Research line 1114-5a | Type-I iron flat block | 2 | QT450-10 | 0.58kg |
| Research line 1114-5b | Type-II iron flat block | | QT450-10 | 0.50kg |
12 | Research line 1114-8 | Plastic dowel | 2 | Fiberglass Polyamide 66 | 0.48kg |
13 | Research line 1114-10 | Height-adjusting plate under rail | 1 | High-density polyethylene | 25.4cm3/mm |
14 | Research line 1114-12 | Height-adjusting plate under tie plate | 1 | High-density polyethylene | 34.6cm3/mm |
Features
The follows are features and structure features of WJ-2 rail fastening system:
Features of WJ-rail fastener system:
The main design parameters and features of the fastener are as follows:
- The height of the fastener is 40mm. The height of the track is adjusted by inserting height adjustment pads under the track and under the iron pad. The adjustment amount is 10mm under the rail and 30mm under the iron pad.
- The left and right position adjustment of the fastener is ± 10 mm/track. Continuous stepless adjustment is achieved by moving the iron pad with oblong holes.
- The maximum lateral force of the fastener is 40kN (fatigue load), and the concrete pedestal is not provided with a shoulder.
- A rail bottom slope of 1:40 is set on the iron pad.
- The stiffness of the fastener node is 40~ 60 kN/mm.
- The nuts of the fastener T-bolts are not arranged in an elastic manner. The tightness is required to make the fastener force uniform. The nut torque of the T-bolt is 90 to 100 Nm.
- The tightening torque of the anchor bolt is 300 Nm.
- The pull-out resistance of the embedded insulating sleeve is greater than 100KN.
- The resistance between the guide rail and the support platform is greater than 108Ω.
- The stiffness of the fastener node is 40-60 KN/mm.
Structural features:
The fastener system is a shoulderless clip structure with an iron pad, and its structural features are as follows:
- There is no concrete shoulder in the concrete sleeper or track slab bearing groove, and the iron pad is provided with a 1:40 rail bottom slope. The concrete sleeper or track slab support surface is a flat slope, which can be used for both buried ballastless track with sleepers (double-piece sleepers, long sleepers) and ballastless track with track slabs. The lateral load transmitted by the train is mainly overcome by the friction of the iron pad.
- A rubber pad is set between the bottom of the track and the iron pad to achieve the flexibility of the system. By replacing the rail pads with different stiffness, it can adapt to the operating conditions of the 350 km/h passenger dedicated line and the 250 km/h passenger dedicated line (considering freight) respectively.
- The iron pad is provided with a T-bolt insertion seat and a rail shoulder, and the spring clamp is tightened by tightening the nut of the T-bolt. The matching design of the elastic clamp has a larger elastic range than the existing elastic clamps in my country (all kinds of elastic clamps are 14 mm) and high fatigue strength. When the elastic pad under the lower rigid rail is used, the buckling attenuation of the elastic clamp is small.
- There is an insulating block between the rail shoulder on the iron pad and the rail to improve the insulation performance of the fastener system.
- An insulating pad is set between the iron pad and the concrete sleeper or track plate to buffer the impact of the train load on the concrete sleeper or track plate, while improving the insulation performance of the system. The insulating pad is equipped with ribs and drains around it, which can effectively increase the water film resistance.
Applications
Main applications of WJ-2 fastener system:
-WJ-2 fastener is suitable for ballastless track structures on prestressed concrete beams that require high and low rails, large left and right position adjustment, and long welded rails. It is required to have a smaller line longitudinal resistance.
-WJ-2 rail fastener system is suitable for bridges, where 60 kg/m rails and concrete integral roadbed are laid on the standard gauge of ballastless track on bridges to meet the requirements of high-speed railways
-Applicable to buried sleepers (double-block sleepers, long sleepers) on tunnels and roadbeds, seamless lines and slab ballastless tracks.
