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Type wj-8 elastic clip rail fastener system

China WJ-8 type Elastic Clip Rail Track Fastener System

WJ-8 Rail Fastening System

Fastener Parts:
WJ-8 type The fastener system consists of a screw spike, a flat washer, a rail clip, an insulating block, a gauge baffle, a rail under the pad, an iron rail pad, an rail pad under the iron rail pad, and a pre-embedded sleeve positioned on the concrete sleeper or track plate. When the rail height is adjusted, the height-adjusting pad is used (the height of the rail is lowered and the height of the iron rail pad is lowered)

Application:
The WJ-8 elastic rail clip fastener system is suitable for passenger lines with a maximum axle speed of 350km/h and a CRTSII type ballless track with a shaft weight of 170KN (considering that the axle weight may increase by 10%). The WJ-8 fastener system has been applied to multiple locations and is generally in good condition.

WJ-8 Fastener System Introduction

WJ-8 type fastener system is a kind of ballastless track fastener system developed to meet the technical requirements of passenger line, it is a special fastener system for laying all kinds of non-shoulderless track, which is optimized based on WJ-1 type and WJ-2 type ballastless track fastener system. The fastener system can be applied to sleeper-buried (double-block sleepers and long sleepers) and slab ballastless tracks on bridges, tunnels and subgrades.

WJ-8 Rail Fastening System Parts Details

Serial number  Name  Quantity  Material  Mass or volume  Remarks 
Spiral spike  High quality carbon steel or alloy steel  1.50kg  The S2 type is generally used, and the S3 type is used when the height is greater than 15 mm. 
Flat Washers  Q235-A  0.138kg    
W1 type elastic clip  60Si2MnA  1.44kg  The general section adopts the W1 type, the single elastic rail clip buckle pressure is greater than 9kN, and the elastic stroke is 14mm. 
X2 type elastic clip  1.28 kg  The X2 type is used for the small resistance area. The single spring buckle has a pressure of 6kN and a stroke of 12mm.  
WJ8 insulation block  Glass fiber reinforced nylon PA66  79.0cm3  Type I, used in general locations. 
73.0cm3  Type II, used at rail joints. 
WJ8 gauge baffle  Glass fiber reinforced nylon PA66  718cm3  Normal installation No. 7, select different numbers according to the gauge adjustment. Joint gauge baffle at rail joint 
WJ8 joint gauge baffle 
WJ8 rubber pad  Natural rubber or synthetic rubber  140cm3  Select one of them according to the specific requirements of the line resistance. The composite backing plate is formed by vulcanizing a 1.2 mm thick 1Cr18Ni9Ti stainless steel plate and rubber. Do not use reclaimed rubber 
WJ8 composite pad  rubber  110cm3 
 stainless steel  0.25kg 
WJ8 iron rail pad  QT450-10  6.80kg    
WJ8 iron rail pad under the rail pad  Thermoplastic elastomer (foaming pad)  540cm3  The static stiffness of the A-type pad is 30~40 kN/mm, which is suitable for the 250 km/h passenger dedicated line (considering freight transportation); 
The static stiffness of the B-type pad is 20~26 kN/mm, which is suitable for the 350 km/h passenger dedicated line; the dynamic and static stiffness ratio is not more than 2.0. 
Pre-embedded casing D1  Glass fiber reinforced nylon PA66  115cm3  The pull-out resistance of the embedded bushing in the sleeper is not less than 60kN. 
10  WJ8 under-rail fine-tuning pad  Polyethylene injection molding  25cm3/mm  According to the specific situation 
11  WJ8 iron rail pad down the high pad  Polyethylene injection molding  720cm3/10mm  According to the specific situation 

WJ-8 Fastener System Features:

The WJ-8 fastener system is a kind of ballastless track fastener system developed to meet the technical requirements of the German passenger car line fastener system. The fastener system is designed under the limited conditions of the size and position of the original plate type and the double-block ballastless track bearing groove, and is an elastic non-separating fastener structure with an iron rail pad.

WJ-8 Rail Fastening System Parts

The research and development of this fastener focuses on the following aspects:

  • Determine the basic structure of the fastener system to make the structure stable and reasonable;
  • Study and solve the problem that both the conventional buckle pressure spring bar and the small buckle pressure can be installed on the same structure. The elastic rail clips meet the technical requirements for laying the longitudinal resistance of the seamless line on the roadbed, tunnel and bridge;
  • taking measures to improve the insulation performance of the fastener system;
  • researching the technical measures to improve the flexibility of the system and supporting the development of long-life and high elasticity Damping cushion and high fatigue strength elastic clip suitable for it.

WJ-8 Fastening System Structural Features

The fastener system is a non-shoulder elastic split structure with an iron rail pad, and has the following structural features:

  • The fastener system is an elastic non-separating fastener with iron rail pad. The concrete sleeper or track plate bearing groove is provided with a concrete retaining shoulder. The lateral load of the train transmitted from the rail passes through the iron rail pad and the gauge baffle, and finally transmits To the concrete shoulder, the position of the lateral load is reduced, making the structure more stable.
  • The rail shoulder pad is provided on the iron rail pad plate, and the insulating block made of engineering plastic is arranged between the shoulder and the rail, which not only can buffer the impact of the rail on the iron rail pad, but also greatly improve the insulation performance of the fastener system, especially the system. Insulation resistance during rainfall;
  • A gauge baffle made of engineering plastic is placed between the iron rail pad and the concrete shoulder to maintain and adjust the gauge distance and at the same time to provide insulation;
  • A variety of elastic rail clips (conventional buckle pressure rail clips and small buckle pressure rail clips) can be installed on the same iron rail pad. Different rails (rubber pads or composite pads) with different friction coefficients can be used to obtain different lines. Resistance can be used for both areas requiring large resistance and for areas requiring small resistance to meet the requirements of laying seamless lines under various line conditions.
  • When the fasteners are assembled and fastened, the front end of the middle leg of the elastic clip is in contact with the bottom of the rail, which avoids the insufficient pressure of the spring bar or the stress of the elastic clip when the heightening pad is inserted between the rail and the iron rail pad.
  • The same spring strip as the WJ-7 fastener has a large elastic stroke and high fatigue strength. When the lower stiffness elastic cushion is used, the buckle pressure of the spring strip is less attenuated.
  • The rail pad layer is arranged under the iron rail pad, the fastener system has good elasticity, and the cushion layer is made of long-life thermoplastic elastomer material.

WJ-8 Rail Fastening System Technical Requirements:

Fastener type  WJ-8 type fastener 
Taxonomy  With iron rail pad (thickness 16mm) 
Withstand lateral force  Sustained by concrete shoulders 
Connection with the foundation  Embedded plastic casing 
Embedded member pull-out resistance  Not less than 60kN 
Buckle  Types of  W1 type  Type X2 
   Buckle pressure  >9kN  6kN 
   Strike  14mm  12mm 
   Fastening method  Bolt fastening 
   Tightening torque  About 160Nm  About 110Nm 
Rail longitudinal resistance  >9kN  4kN 
iron rail pad fastening torque  —— 
Elastic cushion  Setting  A cushion layer (rubber pad or composite rubber pad) is arranged under the rail, and an elastic cushion layer (thermoplastic elastomer foaming pad) is arranged under the iron rail pad plate. 
size  Class A  Class B 
   Under rail rubber pad: 175 × 156 × 4 
   rail pad under the iron rail pad 285×150×12 
Under-arc cushion stiffness  >300 kN/mm 
Sub-layer cushion stiffness  30~40kN/mm  20~30kN/mm 
Rail height  High rail surface  208 
Adjustment amount  30mm 
Adjustment method  By adjusting the height of the pad between the rail and the iron rail pad to achieve 10mm adjustment; padding the pad on the sleeper bearing groove to achieve 20mm adjustment. The filling pad can be adjusted steplessly. 
gauge  Adjustment amount  ±10mm 
Adjustment method  It is realized by replacing the gauge baffles of different specifications. 
Adjustment level  Level adjustment, level 1mm 
Rail joint treatment  In general, when the general gauge adjustment amount is large, replace the joint gauge baffle. 
Applicable to ballastless track  Armless track structure 
Drawing number and standard  Research Line 0604, Science and Technology Base [2007] 207 
Application condition  250km/h  350km/h passenger line 

Comparion of WJ-7 and WJ-8 Rail Fastening System

Serial number  project  Performance 
WJ-7 fastener  WJ-8 type fastener 
Adapt to rail type  China 60kg/m rail 
gauge  1435mm 
Track bottom slope  A 1:40 rail bottom slope is placed on the iron rail pad.  A 1:40 rail bottom slope is placed on the sleeper or track board. 
Rail longitudinal resistance  In general, each group of fasteners is larger than 9kN; for small resistance sections, each group of fasteners is about 4kN. 
System flexibility  The static stiffness of the A-type rail pad is 30~40kN/mm, which is suitable for the 250km/h passenger dedicated line (considering freight transportation); the static stiffness of the B-type rail pad is 20~30kN/mm, which is suitable for the 350km/h passenger line; 
Dynamic and static stiffness ratio  Not more than 2.0.  Not more than 1.5. 
Fatigue performance  The fastener system is tested according to EN 13146-4 when the height is increased by 30mm. After 3 million load cycles, the parts are not damaged, the gauge length is less than 6mm, and the buckle pressure, the longitudinal resistance of the rail and the static stiffness of the rail joint meet the following requirements. : buckle pressure change ≤ 20%; rail longitudinal resistance change ≤ 20%; node static stiffness change ≤ 25%. 
Insulation resistance  The fastener system is tested according to EN13146-5. The insulation resistance between the two rails is greater than 3 Ω·km, and meets the requirements of the track circuit for its insulation resistance. 
Harsh environmental conditions  The fastener system can be successfully disassembled with a manual disassembly tool after the 300h salt spray test described in EN13146-6. 
10  Rail left and right position adjustment  The adjustment of the left and right position of the single-strand rail: -6 ~ +6mm; gauge adjustment: -12 ~ +12mm, continuous stepless adjustment.  The adjustment of the left and right position of the single-strand rail: -5 to +5 mm; the gauge adjustment: -10 to +10 mm, and the adjustment level is 1 mm. 
11  Rail height position adjustment  Rail height adjustment position: 30mm; 
12  Buckle pressure and range  Commonly used elastic rail clips (W1 type): single elastic rail clip buckle pressure is greater than 9kN, and the elastic stroke is 14mm; small resistance elastic rail clip (X2 type): single elastic rail clip buckle pressure is 6kN, and the elastic stroke is 12mm. 
13  Pull-out resistance of embedded bushings in sleepers  Not less than 100kN.  Not less than 60kN. 
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