Adjustable Mold System for Railway Switch Ties
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Solution Overview
Problem
The existing methods for producing switch sleepers are complex, inflexible, and require significant space due to the need for multiple prestressing beds of different lengths and fastening positions, making the process slow and inefficient.
Innovation Solution
A circulation process involving adaptable sleeper molds with siding plates and inner molds allows for the production of switch sleepers of varying lengths and fastening positions, using automatic tensioning of tie rods and concrete pouring, enabling flexible and efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple prestressing beds of different lengths are used to produce switch sleepers of varying lengths, then the required manufacturing precision and adaptability are achieved, but the device complexity and space requirements increase significantly
Solution Approach 1:
The patent applies universality by designing a single prestressing bed that can produce switch sleepers of multiple different lengths. The mold assembly includes adjustable components (mold halves, end forms, siding plates) that can be reconfigured for different sleeper geometries, allowing one device to perform multiple functions that previously required several separate prestressing beds
Solution Approach 2:
The patent implements dynamics through the adjustable and reconfigurable mold assembly. The mold halves, end forms, and siding plates can be dynamically adjusted during the manufacturing process to accommodate different sleeper lengths and fastening positions, transforming a static fixed-geometry system into a dynamic adaptable one
2Adaptability or versatility
If multiple prestressing beds of different lengths are used to produce switch sleepers of varying lengths, then the required manufacturing precision and adaptability are achieved, but the space requirements increase significantly
Solution Approach 1:
The patent applies universality by designing a single prestressing bed that can produce switch sleepers of multiple different lengths. The mold assembly includes adjustable components (mold halves, end forms, siding plates) that can be reconfigured for different sleeper geometries, allowing one device to perform multiple functions that previously required several separate prestressing beds
Solution Approach 2:
The patent merges the functionality of multiple separate prestressing beds into a single integrated device. By combining the capacity to produce various sleeper lengths and fastening positions in one prestressing bed, the total space requirement is reduced while maintaining the ability to manufacture diverse switch sleeper configurations
3Strength
If traditional prestressing methods with multiple rods are used, then the structural strength is achieved, but the manufacturing time and production speed increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling the mold halves, end forms, and siding plates in the desired configuration before pouring the concrete. The prestressing rods are also pre-positioned and tensioning devices are prepared in advance, allowing the actual prestressing and concrete hardening to proceed more efficiently without delays during the manufacturing process
Solution Approach 2:
The patent implements continuity of useful action through the automated tensioning system that continuously applies and maintains the required prestress force on the rods during concrete hardening. The circulation process allows for continuous production with minimal interruption, as molds can be prepared and positioned while previous batches are curing
4Strength
If traditional prestressing methods are used, then the structural strength is achieved, but the production process becomes slow and inflexible
Solution Approach 1:
The patent applies preliminary action by pre-assembling the mold halves, end forms, and siding plates in the desired configuration before pouring the concrete. The prestressing rods are also pre-positioned and tensioning devices are prepared in advance, allowing the actual prestressing and concrete hardening to proceed more efficiently without delays during the manufacturing process
Solution Approach 2:
The patent implements continuity of useful action through the automated tensioning system that continuously applies and maintains the required prestress force on the rods during concrete hardening. The circulation process allows for continuous production with minimal interruption, as molds can be prepared and positioned while previous batches are curing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the production of switch sleepers by allowing for adjustable sleeper shapes and fastening positions, reducing production time and space requirements while enabling the simultaneous manufacturing of multiple sleepers, thereby enhancing manufacturing efficiency and flexibility.
Implementation Method 1
automatic simultaneous tensioning of the tie rods with pairs of spindles, each tie rod being tensioned individually
Implementation Method 2
allowing the switch sleeper to harden
Data Source
Figure 1A~1D
Figure 2A~2C
Figure 3A~3C
AI summary
Disclosed is a method for continuously producing switch ties which differ from one another with respect to the length thereof and the mounting position of rail fastenings. Said method comprises the following steps: - one or more supporting metal sheets and/or one or more internal molds are mounted in a tie mold (1) according to the length and the shape of the switch tie to be produced, or at least one tie mold is used which is adapted to the geometry of the switch tie to be produced; - bracing bars (5) are inserted as a reinforcement; - the bracing bars are simultaneously tightened in an automatic manner by means of pairs of spindles, each bracing bar being individually tightened; - concrete is filled into the tie mold (4); - the switch tie (11) is allowed to set; - the switch tie is removed from the mold.