Grooved rail and method for producing and dismantling a grooved rail

Abstract

The invention relates to a grooved rail for a rail vehicle, comprising a rail head (1) with a running surface (2) for a wheel of the rail vehicle and an adjoining groove (3) for receiving a wheel flange, a plurality of projections (4) arranged at intervals in the groove (3) along a longitudinal direction (I) of the rail, and a filler profile (7) that partially fills the groove (3), receives the projections (4) on a lower profile section, and extends beyond the projections (4) along a height of the groove (3). The lower profile section has an insert (9) extending along the longitudinal direction (I) of the rail. The invention also relates to a method for disassembling a grooved rail, wherein, starting from a point of attachment, the filler profile (7) is lifted out of the groove (3), separates from the projections (4), and is removed as a single, continuous body.

Description

[0001] The invention relates to a grooved rail for a rail vehicle with a rail head having a running surface for a wheel of the rail vehicle and an adjoining groove for receiving a wheel flange of the wheel, with a plurality of projections which are arranged at a distance from each other in the groove along a longitudinal direction of the rail and with a filler profile which partially fills the groove, receives the projections on a lower profile section and extends along a height of the groove beyond the projections.

[0002] The invention also relates to a method for manufacturing such a grooved rail and a method for disassembling the grooved rail.

[0003] Grooved rails are used particularly for tram tracks, where the grooved rail is embedded, for example, in a road surface. The groove provides a clearance to accommodate the wheel flange of a rail vehicle (see, for example, "Railway Vehicle Technology", p. 159, Joachim Ihme, 2nd edition 2019, ISBN 978-3-658-24922-9 and EP 1 809 811 B1 with further references).

[0004] Grooved rails are frequently installed along roads shared with other road users such as cars, trucks, motorcycles, pedestrians, cyclists, scooters, and the like. In a typical design, usually consisting of a single metal grooved rail body, the groove runs alongside the running surface of the rail head and is formed by a groove base, a rail head flank, and an opposing guide rail flank. Such a groove typically tapers towards the groove base in an approximately U-shape.

[0005] It is well known that bicycles, in particular, face a serious risk of falling if a wheel gets caught in the groove. With typical dimensions, the wheels of a bicycle can penetrate deep into the groove, unexpectedly forcing the cyclist in a potentially undesirable direction. A particularly problematic aspect is that a wheel caught in the groove is also laterally blocked by the opposing sides, preventing the usual, often unconscious, balancing and steering movements of the bicycle, thus causing a loss of balance. Depending on the traffic situation and the cyclist's speed, this can result in serious accidents, potentially involving other road users.Other road users, such as wheelchair users, inline skaters, pedestrians, especially pedestrians with walkers, rolling suitcases or the like, also face a certain risk of accident or impairment.

[0006] Against this background, it is known from the prior art to at least partially fill the groove of a grooved rail with a profile, thus protecting bicycle wheels from penetrating too deeply. It is not absolutely necessary for the profile to completely fill the groove. If the profile only partially fills the groove, a shallower but wider depression remains, thereby avoiding or at least significantly reducing the dangers described above. For example, a bicycle wheel can usually be steered out of a sufficiently shallow and wide depression.

[0007] According to DE 87 07 445 U1, DE 198 59 708 C1 and DE 10 2022 110 698 A1, hollow chamber profiles are proposed that can be inserted into the groove of a grooved rail body and prevent, for example, a bicycle wheel from penetrating too deeply. If, on the other hand, the grooved rail is traversed by a rail vehicle such as a tram, the provision of at least one hollow chamber makes the hollow chamber profile sufficiently flexible to accommodate the wheel flanges, with the hollow chamber profile elastically deforming back to its original shape after a section has been traversed.

[0008] This results in considerable stress on the hollow chamber profile, meaning that even when using relatively high-quality and durable materials, damage to the hollow profile can occur within relatively short time intervals, necessitating its replacement. Such systems have not proven effective in practice.

[0009] According to EP 2 298 991 B1 and EP 3 024 982 B1, an elastomeric body is provided as a groove filler, which essentially fills the groove and can then deform due to its elasticity when a wheel passes over it. Here, too, the problem of increased wear due to regular, recurring contact arises. This also applies if, according to EP 3 024 982 B1, a reinforcing layer is arranged on one upper surface of the elastomeric body. The elastomeric bodies can be attached to the smooth bottom of the groove with adhesive or tape.

[0010] Alternatively, grooved rails of the generic type are known from GB 2 546 311 A and DE 10 2021 004 144 A1, which have projections within the groove, wherein a filler profile accommodates the projections on a lower profile section.

[0011] While according to GB 2 546 311 A the groove is essentially filled, and the described wear problem can occur there, according to DE 10 2021 004 144 A1 the groove is not completely filled, so that a wheel flange of the rail vehicle can run above the filler profile without direct contact with the filler profile. Even if the wheel flange comes into contact with the filler profile due to wear of the rail head running surface, the filler profile can then also be locally worn or eroded without significantly impairing the desired safety function. Preferably, the projections have a mushroom shape, a hook shape, or barbs and recesses to enable a particularly intimate, positive-locking connection with the filler profile, which is formed by a casting compound, even in the vertical direction.

[0012] The grooved rail disclosed in DE 10 2021 004 144 A1 is characterized by good functional properties and, in particular, good protective effect for cyclists.

[0013] According to EP 4 177 399 A1, an alternative approach is known to provide recesses in the groove base instead of projections in order to allow anchoring of the filler profile.

[0014] The present invention is based on the objective of achieving improved functional properties of the grooved rail, particularly during long-term use.

[0015] The subject matter of the invention and the solution to the problem are a grooved rail according to claim 1, a method for manufacturing a grooved rail according to claim 13, and a method for disassembling a grooved rail according to claim 14.

[0016] The invention relates to a grooved rail for a rail vehicle, comprising a rail head with a running surface for a wheel of the rail vehicle and an adjoining groove for receiving a wheel flange. Furthermore, a plurality of projections are provided, which are arranged at intervals along the longitudinal direction of the rail in the groove. A filler profile fills the groove at least partially, and preferably only partially, wherein the filler profile receives the projections at a lower profile section and extends beyond the projections. Because the filler profile receives the projections, or the projections engage with the filler profile, a positive fit is achieved along the longitudinal direction of the rail. The filler profile is thereby fixed and cannot slip along the longitudinal direction.Since the filler profile accommodates the protrusions, a certain degree of fixation is also achieved along the height of the groove, i.e., in a vertical direction. As shown below, however, an excessively tight interlocking connection using a mushroom shape, barbs, or the like is preferably not provided. The protrusions generally allow for sufficient fixation of the filler profile in the groove.

[0017] According to the invention, the lower profile section has an insert extending along the longitudinal direction of the rail. Such an insert can, in the usual use of the grooved rail, contribute to a certain increase in the strength of the infill profile by forming a composite, thus protecting cyclists and other road users. However, in essential embodiments of the invention, this is either not significant or only of minor importance.

[0018] The insert is also usually not necessary for the actual fastening of the filler profile in the groove, because sufficiently secure fixing is achieved by the provided projections.

[0019] The insert extending along the longitudinal direction of the rail is provided within the scope of the invention, in particular, to facilitate the removal of the filler profile during disassembly, especially for reconditioning, of the grooved rail. This allows the filler profile to be held together to a certain extent when removed from the insert. Preferably, this enables removal as a single, cohesive unit.

[0020] It should be noted that the filler profile can be made of various, preferably polymeric, materials, including thermoplastics, thermosets, elastomers, or bitumen. These materials can be soft and flexible, so that without the insert extending along the longitudinal direction of the rail, tearing of the filler profile during removal is unavoidable. Furthermore, removal may be necessary if the filler profile is damaged, worn, or brittle due to aging. Such factors can also contribute to a reduction in strength.

[0021] In this case, stabilization by the insert extending along the longitudinal direction of the rail is of particular importance for the removal of the filler profile, whereby the person skilled in the art can select an insert with a suitable strength - if necessary also by means of orienting tests.

[0022] As previously explained, alternative approaches are known from the prior art, whereby the filling profile either only partially or essentially completely fills the groove, with the inventive development being advantageously applicable to both approaches.

[0023] With a filler profile that only partially fills the groove, sufficient protection and a comparatively low tendency to wear can be achieved. With a filler profile that essentially fills the entire groove, the profile must be deformable, particularly elastically deformable, to accommodate the wheel flange. However, increased wear can occur due to direct contact and deformation. On the other hand, small steps and ledges in the groove, as well as the accumulation of dirt, can then be avoided or at least largely prevented. Specifically within the scope of the invention, the filler profile is significantly easier to remove and therefore easier to replace when worn.

[0024] According to a preferred embodiment of the invention, the filling profile is formed by a casting compound, in particular a cured casting compound. A two-component (2K) casting compound is particularly suitable, which cures through a chemical reaction when the two components are joined. A suitable example is a two-component sealant based on polysulfide polymer, such as the one available from Dortmunder Gussasphalt GmbH & Co. KG under the brand name Proxan®.

[0025] Within the scope of the invention, the insert can be adjacent to the potting compound or at least partially embedded in the potting compound. At a minimum, the insert is arranged in the lower profile section of the filler profile, so that when removed from above, the entire filler profile can be stabilized and, in a sense, supported by the insert.

[0026] Preferably, the projections extend through the insert. This makes it particularly easy to reliably separate the entire filling profile from the projections during disassembly.

[0027] As further explained below, the insert can have differently designed openings and / or be placed around the projections along the longitudinal direction of the rail.

[0028] According to a preferred embodiment of the invention, the projections are designed as bolts, in particular cylindrical bolts. Bolts, and especially cylindrical bolts, have a simple shape and can be easily arranged in the groove. For example, metallic bolts can be easily welded to a conventional metallic grooved rail body, resulting in a particularly durable and reliable connection. Simple cylindrical bolts, in particular, can be processed very easily, quickly, and effectively.

[0029] According to a preferred embodiment, a longitudinal axis of the projections is vertically oriented, particularly in the form of bolts and especially preferably cylindrical bolts, wherein the projections are also preferably materially bonded to a bottom of the groove, in particular welded.

[0030] Bolts, and in particular simple cylindrical bolts, are also particularly advantageous with regard to their function within the scope of the invention. Cylindrical bolts, as projections, initially ensure good fixation of the filler profile along the longitudinal direction, so that it is held particularly securely even under loads, thermal distortions, or the like.

[0031] Especially when using a casting compound, and particularly a hardening compound, this will also adhere to the projections. However, in a cylindrical shape, a tight, form-fitting interlock in the vertical direction is avoided, so that with a certain amount of force the filling profile can be released and then preferably removed as a single, continuous piece. Usually, however, this also requires considerable force, so that, within the scope of the invention, very good protection against deliberate damage by vandalism is achieved.

[0032] In principle, it is possible for the bolts to be cylindrical bolts with a thread or serrations on the outer surface, whereby the thread or serrations allow for a certain degree of interlocking. These serrations can be released during disassembly without tearing the core profile.

[0033] Within the scope of the invention, the term "cylindrical bolt" refers in particular to a circular cylindrical shape, but is not limited to this. Cylindrical bolts can also have a rectangular, in particular square, or any other base shape that deviates from a circle.

[0034] Furthermore, the cylinder bolts are usually designed as solid cylinders, although the invention is not limited to this. For example, hollow cylindrical shapes can also be provided, in which case the cylinder bolts can be formed as pipe sections.

[0035] Considering the typical geometry of the grooved rail body, the cylindrical bolts can have a diameter between 5 mm and 9 mm and / or a height between 9 mm and 14 mm. At these dimensions, the bolts offer sufficient strength and a good connection with the filler profile, and can also be easily welded in place. Smaller bolts have lower strength. Larger bolts, on the other hand, require more material, are more difficult to install due to the typical curvature at the bottom of the groove, and are more susceptible to weakening when the filler profile is removed or under other mechanical stress. Furthermore, it is more difficult to position the insert with an opening at the projections or to wrap it around them.

[0036] The projections, preferably designed as bolts, are spaced apart along the longitudinal direction of the rail. It is possible to provide a uniform spacing or to adjust the spacing to the expected loads.

[0037] Within the scope of the invention, it can be provided, for example, that the projections following one another along the longitudinal direction of the rail have a distance between 3 cm and 300 cm, in particular between 10 cm and 100 cm.

[0038] Within the scope of the invention, the insert can in particular be formed by a strip of material extending in the longitudinal direction of the rail or at least by a strand extending in the longitudinal direction of the rail.

[0039] The material strip can have an open structure or be provided as a closed band, in which case, in the case of a closed band, openings are expediently formed at the projections.

[0040] Suitable materials include woven or knitted textile structures and materials. In both weaving and knitting processes, net-like structures can be created directly within the textile process. A strip of material can then be placed over the protrusions at the openings of this net-like structure, allowing the protrusions to extend through the interlining.

[0041] The material strip can also be formed as a closed or essentially closed band. Textile structures are suitable for this purpose, provided they have no macroscopic openings apart from the usual individual meshes and are thus perceived as essentially closed materials. Films, nonwoven materials, and similar materials are also suitable. Naturally, different layers can also be combined.

[0042] If the material strip is formed as a closed or essentially closed band, openings for the protrusions can be created, for example, by punching or cutting. Depending on the material, it is also possible to simply pierce the protrusions through the material strip when inserting the insert.

[0043] The material strip can be made at least partially of plastic. Particularly in textile structures, in addition to plastic threads, other materials such as natural fibers, glass or carbon fiber fabrics, wire mesh, or the like are also suitable.

[0044] The core can also be formed as a single strand or an arrangement of several strands. Threads, cords, ropes, or similar materials can be used as strands. In addition to polymeric materials, plant fibers and raw materials, as well as metallic materials such as wires, are also suitable.

[0045] When designed as a material strip, it can, for example, have a width between 10 mm and 40 mm. The width is chosen so that the material strip can still be guided around projections of a preferred size on both sides when creating openings, and on the other hand, is not too wide.

[0046] Within the scope of the invention, it is advantageous if the insert is not too strongly bonded to the groove, so that the entire filling profile, including the insert, can be removed with minimal force. In particular, it should be avoided that the insert itself can tear during removal. According to a particularly preferred embodiment of the invention, the insert is not directly bonded to the groove, for example, it is not directly glued in place.

[0047] The invention also relates to a method for manufacturing the grooved rail described above, wherein a grooved rail body extending in a longitudinal direction is provided with a running surface for a wheel of a rail vehicle and an adjoining groove for receiving a wheel flange of the wheel, wherein projections are provided as separate parts and are joined to the groove along the longitudinal direction of the rail at a distance from each other in a materially bonded manner, and wherein subsequently a potting compound, in particular a hardening potting compound, is filled into the groove in such a way that it surrounds and covers the projections.

[0048] According to the invention, it is provided that, before or during the pouring of the potting compound, an insert extending along the longitudinal direction of the rail is placed in the groove and covered by the potting compound, in particular completely covered. Advantageously, the insert is arranged such that the projections extend through the insert, the insert being able to have a mesh structure or prepared openings for this purpose, or even be pierced by the projections during insertion.

[0049] In principle, it is conceivable to equip the grooved rail body with the protrusions and the potting compound as described at the factory. However, the method for manufacturing the grooved rail is usually used on already assembled grooved rail bodies, which may already be in use as track.

[0050] When working with an existing track, it is advisable to first prepare and / or pretreat the grooved rail body.

[0051] For example, cleaning with a broom, a pressure washer, or similar equipment is advisable. The groove can then be ground to remove contaminants, rust deposits, or the like, resulting in a virtually metallically clean surface. Drying with a torch flame or other heat source is also possible, after which the protrusions, provided as separate parts, can be attached. For example, bolt-shaped protrusions can be welded to the bottom of the groove using a stud welding machine, with the relevant areas being preheated as a precaution.

[0052] The potting compound, especially a two-component (2K) compound, can then be applied. This application can also be done mechanically, for example using a dispensing nozzle.

[0053] Depending on the type of potting compound, applying a primer may be necessary before applying the compound itself. The primer can be specifically formulated for the material combination of the grooved rail body and the potting compound. Such a primer can improve adhesion.

[0054] Depending on the material of the casting compound, it can be leveled or smoothed to the desired height, and depending on the material, subsequent grinding to a desired height is also possible.

[0055] As explained earlier, the filler profile preferably only partially fills the groove. For example, the groove height of a new grooved rail body might be approximately 47 mm, while the wheel flanges of typical trams have a flange depth of 20 mm to 23 mm. Therefore, for example, the filler profile of a new grooved rail body could be formed with a height of approximately 23 mm from the ground, leaving a certain gap to the wheel flange when the rail is traversed. Depending on the specific circumstances and the wear of an existing track, the filler profile can, of course, also be formed with the grout at a lower or greater height.

[0056] The invention also relates to a method for disassembling the previously described grooved rail, wherein, starting from a starting point, the filler profile is lifted out of the groove, successively separates from the projections and, in particular due to reinforcement by means of the insert, is removed as a single, continuous body.

[0057] Such a removal can be used in particular for reconditioning the grooved rail, whereby new potting compound, in particular hardening casting compound, can then be added as described above.

[0058] The invention is explained below with the aid of figures. These show: Fig. 1 a grooved rail according to the invention for a rail vehicle, Fig. 2A, 2B variants of the grooved rail in a simplified sectional view, Fig. 3A-3D alternative designs of inserts of the grooved rail in the area of ​​a projection, Fig. 4 a dissection of the grooved rail.

[0059] The Fig. 1 shows a grooved rail for a rail vehicle with a rail head 1 which has on one upper side a running surface 2 for a wheel of the rail vehicle and an adjoining groove 3 for receiving a wheel flange of the wheel.

[0060] Furthermore, a multitude of projections 4 are provided, which are arranged at intervals in the groove 3 along a longitudinal rail direction I. The projections 4 are designed as cylindrical bolts and are vertically oriented from a base 5 of the groove 3. Furthermore, already in the Fig. 1 to recognize that the projections 4 in the form of cylinder bolts have a knurling 6 or a thread on the outer surface.

[0061] The projections 4, designed as cylindrical bolts, can, for example, have a height between 9 mm and 14 mm, in particular between 10 mm and 12 mm, along the vertical direction z, and a diameter between 5 mm and 9 mm, particularly preferably about 6 mm.

[0062] In the Fig. 1 It can further be seen that the groove 3 is only partially filled by a filler profile 7, which is formed by a cured potting compound 8, in particular a two-component potting compound, and an insert 9. The potting compound 8 extends around the projections 4, which are thus received by a lower profile section of the filler profile 7. The projections 4 therefore hold the filler profile 7 particularly effectively in a positive fit along the longitudinal direction of the rail.

[0063] Furthermore, it can be seen that insert 9 is located on the lower profile section. It can also be seen that the projections 4 extend through insert 9.

[0064] For this purpose, the insert 9 can be placed in the groove 3 before or during the filling of the potting compound 8, whereby the insert 9 is then completely covered by the potting compound 8.

[0065] The Figuren 2A und 2B Four variants of the present invention are shown in a simplified cross-section in the region of one of the projections. Fig. 2A The insert 9 borders the potting compound 8. For this purpose, it is possible, for example, to insert the insert 9 first during the manufacture of the grooved rail according to the invention, before the potting compound 8 is applied. However, a primer (not shown) can already be applied to the groove 3 before the insert 9 is attached.

[0066] According to the Fig. 2B In contrast, the insert 9 is embedded in the potting compound 8. Such a configuration can be achieved, for example, if the insert 9 is created during the manufacturing process while the potting compound is being poured, or if the potting compound passes through an openly designed insert 9. When attaching the insert 9 during the pouring of the potting compound 8, the process can be carried out such that, according to the Fig. 2B a certain part of the casting compound 8 is arranged below the insert 9, but even then the insert 9 is expediently arranged in the lower profile section of the filling profile 7 and is penetrated by the projections 4.

[0067] The Figuren 3A bis 3D These show exemplary different design possibilities for the insert, each in the area of ​​a projection 4.

[0068] According to the Figuren 3A bis 3C Insert 9 is provided as a strip of material. According to the Fig. 3A The material strip has the form of a net with numerous openings. The insert 9 can also be penetrated by the projections 4 at the openings of the net. To form a net structure, woven fabrics, knitted fabrics, braids, or similar materials are used, which can be made, for example, from suitable polymer fibers, natural fibers, glass fibers, carbon fibers, wire, or other materials. The arrangement of multiple layers and / or the processing of different fibers are also possible.

[0069] The Fig. 3B Figure 1 shows an example of a material strip formed from a nonwoven fabric and penetrated by the projections 4. These openings can be created by punching, incisions, or simply by piercing the projections 4.

[0070] The same applies to the one in the Fig. 3C The depicted material strip is provided as a closed or substantially closed band with openings at the projections 4. The closed material strip can, for example, be formed from a textile without macroscopic openings, a film, or the like. It is also understood that, in principle, several layers with different structures can be combined to form an insert 9 in the manner of a composite material.

[0071] The Fig. 3D Finally, an inlay 9 is shown, which is formed from several strands 10, with the strands 10 being laid around the projections 4.

[0072] The Fig. 4Finally, a schematic representation shows a method for disassembling the grooved rail, whereby, starting from a point of attachment, the filler profile 7 is lifted out of the groove 3. In doing so, the filler profile 7 gradually separates from the projections 3 and can be removed as a single, continuous piece. This is possible in particular because the insert 9 provides reinforcement in the lower region of the filler profile 7 and especially in the area of ​​the projections 9.

Claims

1. Grooved rail for a rail vehicle with a rail head (1) having a running surface (2) for a wheel of the rail vehicle and an adjoining groove (3) for receiving a wheel flange, with a plurality of projections (4) which are arranged at intervals in the groove (3) along a longitudinal direction (I) of the rail and with a filler profile (7) which partially fills the groove (3), receives the projections (4) at a lower profile section and extends along a height of the groove (3) beyond the projections (4), characterized by the fact that the lower profile section has an insert (9) extending along the longitudinal direction (I) of the rail.

2. Grooved rail according to claim 1, characterized by the fact that The filling profile (7) is formed by a potting compound (8), in particular a cured 2K potting compound, and the insert (9).

3. Grooved rail according to claim 2, characterized by the fact thatthe insert (9) borders the potting compound (8) or is at least partially embedded in the potting compound (8).

4. Grooved rail according to one of claims 1 to 3, characterized by the fact that the projections (4) are designed as bolts, in particular cylinder bolts.

5. Grooved rail according to claim 4, characterized by the fact that The bolts, being cylindrical bolts, have a diameter between 5 mm and 9 mm and / or a height between 9 mm and 14 mm.

6. Grooved rail according to claim 4 or 5, characterized by the fact that the bolts, as cylinder bolts, have a thread or a knurling on the outer surface (6) 7. Grooved rail according to one of claims 1 to 6, characterized by the fact that the projections (4) are materially connected to a base (5) of the groove (3), in particular welded.

8. Grooved rail according to one of claims 1 to 7, characterized by the fact thatthe consecutive projections (4) along the longitudinal direction (I) of the rail have a distance between 3 cm and 300 cm from each other.

9. Grooved rail according to one of claims 1 to 8, characterized by the fact that the projections (4) extend through the insert (9) 10. Grooved rail according to one of claims 1 to 9, characterized by the fact that the insert (9) is formed by a strip of material running in the longitudinal direction (I) of the rail or at least by a strand (10) running in the longitudinal direction of the rail.

11. Grooved rail according to claim 10, characterized by the fact that the material strip is formed as a net strip or as a closed band with openings at the projections.

12. Grooved sheets according to one of claims 1 to 11, characterized by the fact that the insert (9) is not directly connected to the groove (3).

13. Method for manufacturing a grooved rail according to any one of claims 1 to 12, ∘ wherein a grooved rail body extending in a longitudinal direction (I) of the rail is provided with a running surface (2) for a wheel of a rail vehicle and an adjoining groove (3) for receiving a wheel flange of the wheel, ∘ wherein projections (4) are provided as separate parts and are materially bonded to the groove (3) at a distance from each other along the longitudinal direction (I) of the rail, and ∘ wherein a potting compound (8) is subsequently filled into the groove (3) such that it surrounds and covers the projections (4). characterized by the fact that Before or during the filling of the potting compound (8), an insert (9) extending along the longitudinal direction (I) of the rail is placed in the groove (3) and covered by the potting compound (8).

14. Method for dismantling a grooved rail according to one of claims 1 to 12, wherein, starting from a starting point, the filler profile (7) is lifted out of the groove (3), separates from the projections (4) and is removed as a single, continuous body.

Images