A double-sided mosaic crossing
By using a double-sided inlaid frog structure, and employing an integrated insert connector to connect with the wing rail and the frog rail, combined with an anti-stress transition zone design, the problems of insufficient strength and stress concentration in traditional frog structures are solved, resulting in a longer service life and greater safety.
Patent Information
- Application Number
- CN202522632239.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-11
- Publication Date
- 2026-11-03
- Estimated Expiration
- 2035-12-11
AI Technical Summary
Traditional turnout structures lack strength and impact resistance, connecting bolts are prone to loosening, and spacers are prone to deformation or wear, posing risks of stress concentration and fatigue cracks, resulting in short service life and safety hazards.
The system adopts a double-sided inlaid frog structure, using integrated insert connectors that are adapted to the shape of the wing rail and the core rail to replace the spacer iron. The insert connectors are connected to the wing rail and the core rail by bolts. The insert connectors are embedded in the core rail-free area and a stress-resistant transition zone is set in the contact area. The wing rail surface is designed with a smooth transition.
It significantly improves the overall structural integrity and strength, effectively disperses the impact load on the rail top, reduces the risk of stress concentration, extends service life, and simplifies the installation and maintenance process.
Smart Images
Figure CN224930885U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of railway equipment technology, and more specifically, to a double-sided inlaid frog. Background Technology
[0002] The frog is a key component of railway tracks, used to allow wheelsets to cross from one track to another. Its performance directly affects train safety and track maintenance costs. Currently, common fixed frog structures mainly consist of components such as the frog rail, wing rails, fork rails, and spacers. Among these, the spacer, as a key component connecting and fixing the wing rails and frog rails, is widely used. However, this traditional structure relying on spacers has several inherent defects: First, it lacks structural strength and impact resistance. The spacer itself is usually connected to the wing rails and frog rails by bolts, and its individual structural strength is limited. Under the long-term impact load of train wheels, the connecting bolts are prone to loosening, and the spacer itself may deform or wear, leading to structural instability, requiring frequent maintenance and replacement, and resulting in a short service life. Second, it suffers from significant stress concentration problems, easily inducing fatigue cracks. More notably, in the contact area between the spacer and the wing rail, especially at both ends, the web and head sections of the wing rail are forced to weaken to make way for the spacer, resulting in abrupt changes in cross-section. These abrupt changes in cross-section will cause severe stress concentration at this point, which can easily become the initiation source of fatigue cracks under cyclic loading, ultimately leading to early failure of the wing rail and posing a safety hazard. Utility Model Content
[0003] The utility model description section introduces a series of simplified concepts, which will be further explained in detail in the detailed description section. This utility model description section is not intended to limit the key features and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.
[0004] To at least partially solve the above problems, this utility model provides a double-sided inlaid frog, comprising: wing rails, insert connectors, and a center rail; two wing rails are symmetrically arranged along the longitudinal direction of the frog, and insert connectors are installed on the inner surfaces of both wing rails; the two insert connectors are arranged opposite to each other, forming a frog area with a center rail and a frog area without a center rail; in the frog area with a center rail, the two insert connectors are relatively fitted and connected to both sides of the center rail; in the frog area without a center rail, the two insert connectors are arranged opposite to each other and abut against each other.
[0005] Furthermore, the side of the insert connector forms a contact area with the side of the wing rail; stress-resistant transition zones are provided at the contact areas at both ends of the insert connector and the wing rail, and these stress-resistant transition zones are formed by the longitudinally extending gap between the thin edge of the insert connector and the side of the wing rail; the wing rail extends smoothly in the contact area without any abrupt changes in cross-section.
[0006] Furthermore, in the stress transition zone, the cross-section of the thin edge of the insert connector is an acute angle of less than 30°.
[0007] Furthermore, the cross-sectional angle of the thin edge of the insert connector is 10°-25°.
[0008] Furthermore, the rail surface in the bonding area of the wing rail has a circular arc transition structure with a radius of curvature of 150mm-300mm.
[0009] Furthermore, the gap width of the stress transition zone is 3mm-5mm.
[0010] Furthermore, the shape of the contact point between the insert connector and the wing rail is adapted to the shape of the wing rail, and the shape of the contact point between the insert connector and the center rail is adapted to the shape of the center rail.
[0011] Furthermore, the wing rail, the insert connector, and the center rail are fixed together by through bolts.
[0012] Furthermore, the insert connector is located at a cross-section of 50mm from the frog throat to the center rail; the rail surface height of the insert connector is higher than that of the wing rail; the insert connector is made of alloy steel and is integrally cast or integrally forged.
[0013] Furthermore, in the centerless fork area, the mating surfaces of the two insert connectors are provided with interlocking concave and convex structures.
[0014] Compared with the prior art, the present invention has at least the following beneficial effects: This utility model discloses a double-sided inlaid frog, which replaces the traditional spacer iron by using an integrated inlaid connector that is adapted to the shape of the wing rail and the core rail. This effectively improves the overall structure and strength, can more effectively disperse the impact load on the rail top, and extend the service life. The two inlaid connectors fit together in the core rail-less area through a concave-convex structure to ensure the stability of this area. At both ends of the contact area between the wing rail and the inlaid connector, a stress-resistant transition zone composed of thin edges and gaps is set. Combined with the smooth transition design of the wing rail surface, it effectively avoids abrupt changes in the wing rail cross section at this point, thereby significantly reducing the risk of stress concentration and preventing crack formation. Furthermore, this frog has fewer structural components, making installation and subsequent maintenance and replacement simpler and more time-saving.
[0015] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description
[0016] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of a double-sided inlaid frog according to the present invention; Figure 2 for Figure 1 Cross-sectional view of the middle AA section (center rail frog area); Figure 3 for Figure 1 Cross-sectional view of the middle BB section (centerless rail frog area); Figure 4 This is a partial structural diagram of the wing rail and the insert connector of this utility model.
[0017] Icons: 1. Wing rail; 2. Insert connector; 3. Core rail; 4. Concave-convex structure; 5. Stress-resistant transition zone. Detailed Implementation
[0018] To enable those skilled in the art to better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0019] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments, so that those skilled in the art can implement it based on the description.
[0020] It should be understood that terms such as “having,” “comprising,” and “including” as used herein do not exclude the presence or addition of one or more other elements or combinations thereof.
[0021] The following is in conjunction with the appendix Figures 1-4 The present invention will be described in further detail below.
[0022] Example 1: As Figures 1-4As shown, a double-sided inlaid frog includes: wing rails 1, insert connectors 2, and a center rail 3; two wing rails 1 are symmetrically arranged along the longitudinal direction of the frog, and insert connectors 2 are installed on the inner surfaces of both wing rails 1; the two insert connectors 2 are arranged opposite each other, forming a center rail frog area and a centerless frog area between them; in the center rail frog area, the two insert connectors 2 are relatively fitted and connected to both sides of the center rail 3; in the centerless frog area, the two insert connectors 2 are arranged opposite each other and abut against each other. The wing rails 1, insert connectors 2, and center rail 3 are fixed together by through bolts. The shape of the contact point between the insert connector 2 and the wing rail 1 is adapted to the shape of the wing rail 1, and the shape of the contact point between the insert connector 2 and the center rail 3 is adapted to the shape of the center rail 3. In the centerless frog area, the mating surfaces of the two insert connectors 2 are provided with mutually interlocking concave-convex structures 4.
[0023] The working principle and technical effects of the above scheme are as follows: This utility model discloses a double-sided inlaid frog, with the center rail 3 as the core and two wing rails 1 symmetrically arranged on both sides. The key insert connector 2 is set on the inner side of the wing rail 1. In the center rail section, the insert connector 2 serves as an intermediate component, and the wing rail 1 and center rail 3 are firmly connected by bolts to form a stable overall frame. In the section without center rail, the insert connectors 2 on both sides are directly connected by the concave and convex structures 4 at the ends, ensuring the structural continuity of this area. The wheel load is transmitted to the insert connector 2 through the wing rail 1 and center rail 3, and then distributed to the entire structure. This invention relates to a double-sided inlaid frog, which replaces scattered spacer irons with an integrated insert connector 2 that matches the shape of the wing rail 1 and the center rail 3. This eliminates weak points in the connection between components, significantly improving the overall structural integrity and strength. It allows the impact load on the rail top to be more effectively transmitted and dispersed to both sides through the insert connector 2, optimizing the force flow path and thus extending the overall service life of the frog. In the centerless rail frog area, the two insert connectors 2 interlock through the concave-convex structure 4 at their ends, achieving not only physical connection but also playing a crucial role in positioning and constraint. This effectively prevents lateral or vertical displacement of the structure in this area, ensuring the smoothness and stability of the wheels when passing through the centerless rail section. In this double-sided inlaid frog, by setting thin edges and longitudinal gaps at both ends of the contact area between the insert connector 2 and the wing rail 1, and ensuring a smooth transition of the wing rail 1 surface at this point, abrupt changes in the cross-section of the wing rail 1 are fundamentally avoided. This allows stress to be transmitted gradually, significantly reducing the stress concentration factor and fundamentally suppressing the risk of fatigue cracks initiating at the ends of the wing rail 1 contact area. In addition, the structure integrates functional components, simplifying the assembly relationship. The main structure can be fixed with a single bolt connection, eliminating the multiple fastening steps of traditional spacer irons, making on-site installation and subsequent replacement and maintenance of the core rail 3 or the insert connector 2 simpler and more time-saving.
[0024] Example 2: As Figures 1-4As shown, the side of the insert connector 2 and the side of the wing rail 1 form a contact area. Stress-resistant transition zones 5 are provided at both ends of the contact area between the insert connector 2 and the wing rail 1. These stress-resistant transition zones 5 are formed by a longitudinally extending gap between the thin edge of the insert connector 2 and the side of the wing rail 1. The wing rail 1 extends smoothly along its surface in the contact area without abrupt changes in cross-section. In the stress-resistant transition zone 5, the cross-section of the thin edge of the insert connector 2 is an acute angle less than 30°. Preferably, the cross-sectional angle of the thin edge of the insert connector 2 is 10°-25°. The wing rail 1 has an arc-shaped transition structure in the contact area, with a radius of curvature of 150mm-300mm. The gap width of the stress-resistant transition zone 5 is 3mm-5mm, effectively preventing high stress from the thin edge of the insert connector 2 contacting the wing rail 1 during use.
[0025] The working principle and technical effects of the above scheme are as follows: In this invention, a double-sided inlaid frog has a contact area formed between the side of the insert connector 2 and the side of the wing rail 1, constituting the basic interface for load transfer. At both ends of the contact area, the insert connector 2 is designed with thin edges, and a longitudinally extending gap is pre-set between it and the side of the wing rail 1, forming a stress-resistant transition zone 5. The core function of this gap is to provide a small amount of free space for the wing rail 1 when it deforms under stress, preventing the rigid end of the insert connector 2 from directly and rigidly pressing against and squeezing the wing rail 1. The wing rail 1 extends smoothly along the contact area without abrupt changes in cross-section, allowing wheel loads to pass smoothly through this area, avoiding stress peaks caused by abrupt changes in geometry. The cross-section of the thin edge of the insert connector 2 is designed with an acute angle of less than 30°. This sharp, thin edge design greatly reduces its own stiffness, making it more flexible under stress, thereby guiding stress to transition smoothly from the solid contact area in the middle to both ends, ultimately dissipating safely. In this invention, a double-sided inlaid frog effectively eliminates the stress concentration phenomenon caused by the abrupt change in the cross-section of the wing rail 1 in traditional structures through the combined effect of the smooth transition of the wing rail 1 surface and the stress-resistant transition zone 5. This solves the industry pain point of fatigue cracks appearing at the end of the wing rail 1 in the contact area. By avoiding high-amplitude alternating stress, the fatigue life of the wing rail 1 and the inlay connector 2 is significantly improved, thereby extending the service life of the entire frog and reducing the frequency of replacement and maintenance costs.
[0026] Example 3: As Figures 1-4 As shown, the insert connector is located at a cross-sectional position of 50mm from the frog throat to the center rail 3; the rail surface height of the insert connector 2 is higher than the rail surface height of the wing rail 1; the insert connector 2 is made of alloy steel and is integrally cast or integrally forged.
[0027] The working principle and technical effects of the above scheme are as follows: In this invention, a double-sided inlaid frog is provided at a 50mm section from the frog throat to the frog rail 3. This arrangement completely covers all critical weak areas from the beginning of wheel load transmission to the frog rail 3 with sufficient bearing width. It provides continuous lateral support for the wing rail 1 and frog rail 3 in the most important sections, integrating the originally scattered components into a whole frame structure, greatly enhancing the overall stability and deformation resistance of the frog under impact loads. The rail surface height of the inlaid connector 2 is set higher than that of the wing rail 1, ensuring that when the wheel passes, the inlaid connector 2 becomes the main load-bearing component. The wheel load is preferentially transmitted directly through the high-strength integrated inlaid connector 2, rather than relying entirely on the wing rail 1. This optimizes the force flow path, effectively reduces the stress and wear on the wing rail 1, thereby protecting the wing rail 1 and extending its service life. The insert connector 2 is made of alloy steel and is integrally cast or forged to ensure the high strength and hardness of the component itself. The integral molding process eliminates the weak areas, internal stress and defects that may exist in traditional welding or bolt connections, ensuring the continuity and density of the internal structure.
[0028] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.
[0029] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0030] Although the embodiments of this utility model have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for this utility model. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, this utility model is not limited to the specific details and the illustrations shown and described herein.
Claims
1. A double-sided inlaid frog, characterized in that, include: Wing rail (1), insert connector (2) and center rail (3); two wing rails (1) are symmetrically arranged along the longitudinal direction of the frog, and insert connectors (2) are installed on the inner side of both wing rails (1); the two insert connectors (2) are arranged opposite to each other, forming a center rail frog area and a centerless rail frog area between them; in the center rail frog area, the two insert connectors (2) are connected to the two sides of the center rail (3) respectively; in the centerless rail frog area, the two insert connectors (2) are arranged opposite to each other and are connected to each other.
2. A double-sided inlaid frog according to claim 1, characterized in that, The side of the insert connector (2) and the side of the wing rail (1) form a contact area; stress-resistant transition areas (5) are provided at both ends of the contact area of the insert connector (2) and the wing rail (1). The stress-resistant transition area (5) is formed by the longitudinally extending gap between the thin edge of the insert connector (2) and the side of the wing rail (1); the wing rail (1) extends smoothly on the rail surface in the contact area without abrupt changes in cross section.
3. A double-sided inlaid frog according to claim 2, characterized in that, In the stress transition zone (5), the cross-section of the thin edge of the insert connector (2) is an acute angle with an angle of less than 30°.
4. A double-sided inlaid frog according to claim 3, characterized in that, The cross-sectional angle of the thin edge of the insert connector (2) is 10°-25°.
5. A double-sided inlaid frog according to claim 2, characterized in that, The wing rail (1) has a circular arc transition structure on the rail surface in the bonding area, and the radius of curvature of the circular arc transition structure is 150mm-300mm.
6. A double-sided inlaid frog according to claim 2, characterized in that, The gap width of the stress transition zone (5) is 3mm-5mm.
7. A double-sided inlaid frog according to claim 1, characterized in that, The shape of the contact point between the insert connector (2) and the wing rail (1) is adapted to the shape of the wing rail (1), and the shape of the contact point between the insert connector (2) and the center rail (3) is adapted to the shape of the center rail (3).
8. A double-sided inlaid frog according to claim 1, characterized in that, The wing rail (1), the insert connector (2), and the core rail (3) are fixed together by through bolts.
9. A double-sided inlaid frog according to claim 1, characterized in that, The insert connector (2) is located at the 50mm section from the frog throat to the center rail (3); the rail surface height of the insert connector (2) is higher than the rail surface height of the wing rail (1); the insert connector (2) is made of alloy steel and is integrally cast or integrally forged.
10. A double-sided inset fork according to claim 1, characterized in that, In the centerless rail fork area, the mating surfaces of the two insert connectors (2) are provided with interlocking concave and convex structures (4).