Method for accurately placing an insert in concrete, apparatus for performing said method , and railway track obtained through the method

The invention relates to civil engineering, in particular the construction of lines of railway. Indeed, this process is particularly advantageous for inserting, in a concrete slab, saddles supporting railway rails. It is also applicable in all cases are sealed in concrete, in a given position, with a precision of the order of a millimeter, an insert which comprises at least one cavity to be filled by concrete for the insert resists significant efforts.

It is known, from DE 3714581, a process for setting up correct a reinforcement in a concrete slab in which firstly Introduced liquid concrete into a mold, is then deposited on the armature concrete always and liquid is fed by vibrating the frame into its correct position.

Known from EP 0117323 a process to set up, accurately relative to a reference line, connecting bars between two slabs concrete to achieve a highway or runway. These bars are placed horizontally and perpendicularly to the plane of the expansion joint. The method comprises at:<ul><li>run a continuous concrete slab and smooth surface;</li><li>then, while the concrete is fresh, push each connecting rod in the fresh concrete by vibrating the bar to liquefy the concrete around this bar during its movement until it reaches a given position: vibration during displacement allow precise positioning with respect to a reference line;</li><li>then set up an expansion joint that cuts the continuous slab and separated into two plates which are connected by the connection bars.</li></ul>

Various methods are known for making a railway track. The channels most common are supported by sleepers laid on ballast. However is carried out ways without sleepers for particular applications, in particular for channel Tram in traffic areas. These channels must be embedded in the floor, and therefore require the said disbursement earthworks. It minimizes the depth of disbursement, to reduce costs and reduce the inconvenience caused to residents and users of road pavements. For this, one realizes lanes with a concrete slab instead of traditional ties. Rails based on the concrete slab by means of known metal parts stools and rubber soles. The stools are attached to the concrete slab, for transmit the forces exerted by the passage of a tramway on this path.

One known method for producing such a path is: <ul><li>join two rails by manually setting spacers templates, adjustable aloft by means of cylinders to define the gauge and altitudes respectively;</li><li>manually set at regular intervals in each rail saddles, between templates; each seat comprising, on one side of the threaded studs of fix this seat rail, and having on another face, anchoring devices adapted to be sealed in concrete;</li><li>adjust these templates to the working plan is the planned altitude and present the required gradients;</li><li>ask recyclable sideforms;</li><li>pouring concrete under the rails and the cuff, so that the devices anchoring stool are covered and embedded in the concrete slab, and that this has a flat surface just below the rails.</li></ul>

This process requires great care for accurate positioning rails by jigs, and it takes time for mounting spacers templates and the establishment of concrete. It is costly in labor. Not being industrial nature, it leaves a large part in the initiative and the expertise of the staff.

The object of the invention is to provide a method for producing a track railway, without crossings, at a lower cost that known method.

The object of the invention is a method to establish with precision an insert in concrete, said insert including one or more cavities to be filled by concrete, comprising:<ul><li>prepare a concrete having a firm consistency;</li><li>implement this concrete, correct and smooth its surface while it is fresh, to give the surface a given position with a given tolerance;</li><li>then, while the concrete is fresh, moving the insert into the concrete, making vibrate the concrete around the insert during its movement until it reaches a given position with a given tolerance;</li></ul>characterized in that it further consists in confining the concrete by means preventing the rise of concrete around of the insert for the establishment of the insert in the concrete, to force the concrete to fill each cavity of the insert.

The method enables to utliserdes inserts with cavities relatively deep without a risk of poor filling. Therefore, it guarantees a very stress resistant anchoring. This property is particularly advantageous for inserts supporting railway rails.

The well characterized method further provides high accuracy through collaboration of the three following characteristics:<ul><li>The fact of vibrating the concrete helps liquefy momentarily vicinity of the point of application of vibration, thus allowing easy insertion, a good coating of submerged parts of the insert, and de facto a good seal. Note the vibrations may be applied through the insert or other independent device of the insert, and positioned in the concrete in the vicinity of the insert.</li><li>The fact that concrete is in place first, it is smoothed and rectified that its surface has a relatively precise position whereby in pressing the insert at a nominal depth (such as insert the anchoring device will be neither too much nor insufficiently covered by the concrete) is placed the insert at a position which is very close of the desired position. Just a small change of the depression to catch a possible position error of the concrete surface. The smallness of this amendment allows very precise adjustment.</li><li>The insert retains this position with this accuracy throughout the duration of the concrete because it found quickly after stopping vibration, firm consistency which prevents displacement of the concrete or of the insert under the action of their weight.</li></ul>

When applied to the embodiment of a railway track comprising rails supported by saddles provided with anchoring devices which may be sealed in concrete, the method according to the invention is characterized in that it consists in Also in:<ul><li>put the concrete in the form of a slab having a unified surface whose position is deducted from the position intended for the track running surface;</li><li>then, while the concrete is fresh, push each seat in the slab concrete, by vibrating the concrete around the seat, until it reaches a given position with a given tolerance.</li></ul>

The method enables to significantly reduce the cost of production a track rail, since there is no step of setting spacers templates, and check its position before pouring concrete. The accuracy obtained on the position of each seat is sufficient to obtain the desired precision for the spacing between the two rails of a track, and the position of the running surface. In addition, the filing of a concrete slab before installing the rails, not after, allows a vector slipform paver which allows pour a concrete slab with very little labor.

According to one embodiment of the preferred embodiment, the method of the invention is characterized in that, to drive a saddle in a slab of concrete, vibrating this saddle, until it reaches a given position with a given tolerance, it consists in slaving the position of the saddle in a predetermined position setpoint, according to three mutually orthogonal axes or an equivalent frame of reference.

The method enables to automate the insertion of the saddle, while providing excellent positional accuracy.

According to one embodiment of the preferred embodiment, the method of the invention is characterized in that, for driving seat until it reaches a position Data, with a given position, it consists:<ul><li>In a first step, to push the saddle with a first set speed, leaving some freedom in the seat in a horizontal plane, and by vibrating this saddle with a frequency and an amplitude of vibration suited to a driving fast, until it reaches a position close to the setpoint;</li><li>then, in a second step, positioning the saddle with a second speed fixed lower than the first, by vibrating this saddle with a frequency and amplitude of vibration suited to fine positioning, until it reaches a position corresponding to the setpoint.</li></ul>

The invention also relates to a device for carrying out the method according to the invention.

Finally, the invention relates to a railroad track obtained by the method of the invention.

The invention will be better understood and other details will appear with the following description of embodiments of the device for the implementation of method according to the invention; and with the figures accompanying this description:<ul><li>1 shows an example of saddle can be used to make a railway track, without sleepers; </li><li>2 shows a sectional view of a railway track comprising this type of saddle, and their stools were inserted by applying the method according the invention;</li><li>Figures 3 and 4 show respectively a top view and a view side, in section, of the main part of an example of embodiment of the device according the invention; this example being an insertion device for inserting a saddle of this type in a concrete slab;</li><li>5 shows an overview of this embodiment;</li><li>Figures 6 to 9 show four successive stages of operation of this embodiment;</li><li>Figures 10, 11, and 12 show two front views and a top view a mobile machine that can simultaneously insert two stools to make a way railway.</li></ul>

The method according to the invention can be used to insert any type of insert metallic or non-metallic, may be sealed in concrete. 1 shows an example of a seat rail of the railway, which can be inserted by applying the method of the invention. This example saddle, referenced 1, comprises:<ul><li>a pressed sheet steel plate, 3;</li><li>and two pins each having a threaded rod, respectively referenced 2 and 4, for fixing a rail on the saddle by screws, and a sealing rod, referenced respectively 9 and 6, having a generally cylindrical shape extending threaded rod, and having asperities, for example circular, ensuring retention in the concrete once it has hardened.</li></ul>

The plate 3 has a generally rectangular, flat and horizontal, with : A vertical edge 11 around its periphery, four reinforcing ribs and two bosses 5 and 10 having slightly inclined vertical walls. These bosses 5 and 10 are designed especially for working with parts, not represented, to be used for subsequent attachment of a rail. In the use is made here, the protrusions 5 and 10 also have the function to provide a free space control to recover a volume equal to the volume of concrete concrete displaced by the sealing rods 6 and 9 when the seat is pressed into the concrete. On the other hand, stools 1 and 1 'comprise a plurality of apertures 7, 12 for the exhaust air when the concrete fills the bowl constituted by the plate 3, its edge 11, and the bosses 5 and 10.

Each stud is fixed to the sole by a force fit, or by welding. The threaded portion of the stud can be protected during all operations of insertion of the saddle by means of a plastic sleeve screwed on this threaded portion.

The method of the invention is applicable not only to this type of insert but also to any other type of insert can be sealed in concrete.

Figure 2 shows in section an exemplary realized railway track using this type of saddle and applying the method of the invention. This 2 shows two rails 12 and 14 fixed respectively to two saddles 13 and 15, by nuts and intermediate pieces in a conventional manner between each nut and the rail.

These two saddles 13 and 15 are sealed in a concrete slab 16 whose surface is planar, each of the two saddles 13 and 15 being pressed into the surface of the slab 16 to a depth such that the plane of these saddles is approximately in the plane of the surface of the slab 16. The concrete fills each seat and thus provides an anchor stronger than if he was assured by the anchor rods.

The altitude of each of the rails 12 and 14 is determined partly by the elevation of the surface of the slab 16 which is manufactured with a given accuracy, of the order of a few millimeters, and secondly depends on the depression of the seat into the concrete slab 16, this recess being adjusted so that the road surface has a given position, accurate to the millimeter. The spacing between the rails 12 and 14 is determined by the distance separating the two stools when they are sealed. he No templates spacers between the rails, or a priori shim.

Figures 3 and 4 show respectively a top view and a view sectional view of the main part of an example of the insertion device specially adapted the insertion of the saddle of the type shown in Figure 1. This example comprises a base consists of a sheet 30 designed to be placed directly on the surface 25 a concrete slab 31 which is to be inserted in a seat. This concrete is fresh, smooth, and has a firm consistency. This plate 30 has a circular opening on which is welded to a vertical tube 21 for the passage of a movable part.

This moving part comprises:<ul><li>a receptacle 28 of polyurethane, having an inner surface conforming to the shape of a saddle and comprising a flexible inner seal 29, the receptacle 28 supported over the entire periphery of the saddle 1 by means of the seal 29; and the receptacle 28 having a circular external shape with a diameter slightly smaller than that of the tube 21 so as to pass into the tube 21 while preventing a rise in concrete in the tube 21 to confine the concrete;</li><li>a support plate 22 made of polyurethane, having a circular shape diameter slightly smaller than the diameter of the tube 21, and supports particularly the receptacle 28 under this plate 22;</li><li>four elastic rubber blocks 24a, 24b, 24c, 24d, fixed to the plate 22;</li><li>two vertical arms 40a and 40b, fixed to the plate 22;</li><li>a vibration device 35, which is fixed on a steel plate 32, the latter being fixed to the top of the four resilient blocks 24a, 24b, 24c, 24d;</li><li>two clamps 23a and 23b, hydraulically operated, fixed to the plate 32, and respectively tightening the threaded rods of the two studs of the seat 1 (Figure 4 only representing the clamp 23a tightening the threaded rod 2);</li><li>eight positioning pins 26a to 26h, whose ends rest on the horizontal surface of the saddle 1 remaining in contact with the virtually vertical walls bosses 5 and 10 to give the saddle 1 January definite position in the plane horizontal, each of these fingers sliding in a sheath, 27a to 27h respectively, attached to the plate 22; four fingers 26a to 26d being secured to a piece 33a (Partially shown in figure4) and four fingers 26e-26h is being integral part not shown but homologous 33b secured to the part 33a via a bracket 39 that is seen from the side in Figure 4.</li></ul>

For clarity, Figure 3 does not represent the vibration device 35, or the parts 33a and 33b or the yoke 39. Figure 4 does not show the hydraulic hoses feeding the clamps and the vibration device.

The vibration device 35 includes one or more vibrators, each vibrator consisting for example of a hydraulic motor with an unbalance. Across 35 vibration device vibrates resulting in its movement the plate 32 which some freedom thanks to elastic blocks 24a to 24d. The clamps 23a and 23b transmit vibration to the anchor rods 9 and 6. Under the action of these vibrations, the concrete is much more fluid in the vicinity of the anchor rods, thereby driving them with less force and get a much more accurate positioning.

5 shows all of this embodiment, representing further including means for vertically displacing the supporting plate 22, and vertically moving the caliper 39. These means comprise:<ul><li>a horizontal beam 45 and two vertical cylindrical guides 43a and 43b, constituting a portico;</li><li>a slider 42 sliding vertically while being guided by the two guides 43a and 43b;</li><li>a first hydraulic cylinder 44 having one end fixed to the beam 45 and the other end fixed to the slider 42;</li><li>the two vertical arms 40a and 40b connecting the slider 42 to the plate support 22;</li><li>a second hydraulic cylinder 41 having one end fixed to the slider 42 and having its other end fixed to the bracket 39 which spans the vibration device 35;</li><li>and a CPU control unit connected:<ul><li>to a position sensor 46 fixed at one end to the beam 45 and on the other hand to the slider 42 to determine the elevation of the saddle 1 with respect to the plate 30 which rests on the surface 25 of the slab 31;</li><li>a position sensor CP integral of the beam 45, to determine the height of the plate 30 relative to a reference plane called laser plane because it is identified by a rotating laser beam in a given plane;</li><li>the actuator 44 by two pipes to actuate;</li><li>the cylinder 41 by two pipes to actuate;</li><li>and vibration device 35 by two pipes to operate it.</li></ul></li></ul>

The control unit UC controls several stages. Figure 6 illustrates a first step during which the seat 1 is placed manually or automatically, inside the receptacle 28, by inserting the threaded rods studs in hydraulic clamps 23a and 23b (The latter is not shown). The cylinders 44 and 41 are retracted, leaving space between the tube 21 and the receptacle 28 for accessing the interior of the latter.

Figure 7 illustrates a second step in which the seat 1 is pressed quickly. Throughout this step, the vibration device 35 is activated with an amplitude and frequency adapted to to facilitate penetration of the saddle 1 in the concrete slab 31, making it more fluid concrete in the vicinity of the anchor rods. 24a rubber blocks, etc ... allow the plate 32 to move slightly in all directions relative to the plate 22. The actuator 44 is actuated to push the seat 1 to a position close to the final position provided, within a few millimeters. The actuator 44 moves: the slider 42, the arms 40a and 40b (not shown), the support plate 22 and the receptacle 28 as are associates. The seat 1 is pushed into the concrete liquefied by vibration. the receptacle 28 is lowered to be adjacent the surface 25 of the concrete slab. he be noted that the guide fingers 26a, etc., are still in the raised position and are not in contact with the saddle 1.

8 illustrates a third step of inserting the seat 1 comprising complete sinking to a lower speed suitable for accurate positioning, until the final planned depth for the seat. The actuator 44 is activated again, but with a lower speed. The vibration device 35 is on, but the amplitude and frequency of vibration are adapted for precise positioning of the seat 1. The receptacle 28 and the plate 30, which are almost contiguous, and confine the concrete force him to go back in the bosses 5 and 10. When the seat has reached the position 1 provided, the vibration device 35 and the actuator 44 are stopped.

9 illustrates a fourth step during which the vibration device 35 is stopped. The cylinder 41 is activated in turn. It lowers the bracket 39 which is secured of the workpiece 33a (partially shown) and the part 33b (not shown), these parts 33a and 33b supporting the fingers 26a, etc ... The yoke 39 drops to abut the plate 32. The ends of fingers 26a, etc. ... then come into contact with the part plane of the seat 1. If the saddle 1 is not perfectly positioned in the horizontal plane, fingers rub against the vertical walls of the protrusions 5 and 10 of the saddle 1 and cause a slight displacement of the saddle 1, in the horizontal plane, to reverse 1 seat in a well defined by eight fingers position. Vibration having oessé, the gradually resumes its concrete firm. The clamps 23a, etc ... are maintained tight, and the fingers 26a, etc. ... are held in this position until that increasing the viscosity of the concrete is sufficient to prevent movement- the saddle during the ascent of the fingers.

Hydraulic clamps 23a and 23b are then commanded to release bolts of the saddle 1. Can the actuator 41 is activated in reverse to back the fingers 26a, etc ... Then the actuator 44 is activated in reverse to back up all the moving part of the insertion device.

Figures 10 and 11 respectively show two front views of a machine spindle for the insertion of two stools simultaneously. In Figure 10, the machine is in a condition to move and prepare for the insertion of a saddle. In Figure 11, the machine is to insert a saddle in a fresh concrete slab 62. Figure 12 shows a top view. In these figures, the machine has already inserted stool 70-76 in a concrete slab 62.

This embodiment includes a mobile platform supporting 52 two insertion devices 51a and 51b identical to each other and which may be similar the insertion device shown in Figures 3 to 5, and which has been described previously. They comprise in particular position sensors 64a, respectively 64b, similar to the PC sensor; and control units UC1, UC2 respectively, analogously to control unit UC. 51a and 51b are mounted on a carriage 63 which is integral with the mobile 52 and platform relative thereto according two horizontal, mutually orthogonal axes. On the other hand, a set of jacks, not represented lowers devices 51a and 51b until their bases (Sheet 30) rest on the surface of the concrete slab 62. The devices 51a and 51b traverse the carriage 63 by the openings 61a and 61b respectively, and through the platform 52 with an opening 62.

The platform 52 is mounted on four tracks 53a, 53b, 53c, 53d, via four articulated horizontal arms 55a, 55b, 55c, 55d, for adjusting the spacing between the tracks, and by means of four vertical legs 57a, 57b, 57c, 57d, to independently adjust the height of each arm 55a, 55b, 55c, 55d, respectively, compared to the tracks 53a, 53b, 53c, 53d, based On the ground.

The position of the platform 52 is controlled along three orthogonal axes, in means of a control unit UC3, so that it follows the profile expected for the raceway, therefore it follows the surface of the slab 62. The legs 54a and 54b respectively support 58a and 58b sensors that follow a parallel guide 57 the profile along the rails to install. This guide door 57 benchmarks, to enslave the position of the platform 52 along two horizontal axes by referring to the guide 57. The platform 52 spans the concrete slab 62 and moves along the slab 62 through motors driving the caterpillars 53a, ..., 53d.

On the other hand, the legs 54a and 54b are respectively sensors 60a and 60b for determining the respective heights of the arms 55a and 55b with respect to a laser plane, considering the height adjustment of the arm relative to the legs 54a and 54b. Knowing these altitudes allows tracking these altitudes to predetermined setpoints for the platform 52 follows the profile of the track.

The concrete used has a firm consistency. The slab 62 has been freshly poured, vibrated in place, rectified and smoothed by a conventional slip form machine, such as those used to make concrete pavement, for motorway. It gives the surface of the slab a position deduced from the position intended for the rolling plane of the track with a precision of the order of 2 millimeters, through servo-controls conventional position.

Insertion devices stool, 51a and 51b, are spaced apart by a corresponding interval the expected range for the rails. The carriage 63 moves together and refines the insertion position with an accuracy of about a millimeter along two horizontal axes, even better than that provided by the platform 52.

The movable carriage 63 carries a position sensor 59 which is used to link the position of the carriage 63 along two horizontal axes, with reference to the position of the same guide 57, but with a finer tolerance than the tolerance on the position of the platform 52. The carriage is moved by two motors, not shown, controlled by a control unit UC4, based on measurements made by the sensor 59 and according to the position intended for both saddles to insert.

The enslavement of insertion devices 51a and 51b along a vertical axis, by the control units UC1 and UC2, to insert each saddle with an accuracy elevation of about one millimeter, even better than the accuracy obtained on the altitude of the surface of the concrete layer 62.

The position control device, referring to the position of a guide and a laser plane position, are conventional devices. But other known types position feedback device could also be used to obtain precise position of each saddle.

According to one embodiment, the insertion devices 51a and 51b could be mounted directly on the machine used to run up the slab concrete 62, instead of the platform 52. The embodiment of this machine will not be described because it is similar to the embodiment of a machine conventionally used for make concrete highways.