Ballast Cleaning Machine Deep Tamping Single Pass
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Solution Overview
Problem
The existing method for cleaning and maintaining ballast tracks requires multiple passes and extensive closure periods, leading to prolonged rail traffic disruptions and increased labor and equipment needs.
Innovation Solution
Implementing a deep tamping process that compacts all layers of new and cleaned ballast in a single pass, followed by stabilization, eliminating the need for separate ballast trains and reducing the number of tamping processes, and utilizing a ballast introduction device to reuse cleaned gravel directly after cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple passes and extensive closure periods are used for ballast cleaning and maintenance, then the quality of the ballast bed can be maintained, but the closure period is prolonged and rail traffic is disrupted for longer
Solution Approach 1:
The patent combines multiple separate operations (ballast removal, cleaning, introduction of cleaned/new ballast, and compaction) into a single integrated cleaning machine that performs all functions in one pass, eliminating the need for multiple separate passes and reducing the closure period while maintaining ballast bed quality
Solution Approach 2:
The cleaning machine introduces cleaned and/or new ballast into the track before compaction occurs, ensuring that the ballast bed is properly prepared with sufficient material in place before the compaction process begins, which maintains quality while reducing overall operation time
2Reliability
If multiple separate machines and ballast trains are used for ballast cleaning and compaction, then the ballast bed can be properly maintained, but the equipment requirements and labor costs increase
Solution Approach 1:
The patent integrates multiple previously separate machines (ballast removal device, ballast introduction device, tamping machine, and stabilization machine) into a single multi-functional cleaning machine, reducing the number of equipment pieces required while maintaining comprehensive ballast bed maintenance capability
Solution Approach 2:
The cleaning machine is designed with multiple functional units that perform different operations (removal, cleaning, introduction, compaction, and stabilization) within a single machine platform, making it a universal device that replaces multiple specialized machines and reducing overall equipment complexity
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 approach shortens the closure period, reduces labor costs, minimizes equipment requirements, and maintains the quality of the ballast bed, allowing for faster rail traffic resumption with improved safety and reduced construction site efforts.
Implementation Method 1
a deep tamping unit (22) for deep compaction of the ballast bed (4) in different depths
Implementation Method 2
The deep tamping unit (22) deep compacts the ballast bed (4) in different depths
Implementation Method 3
The track (2) is stabilized using a stabilization machine (21)
Implementation Method 4
The subsequent stabilization lowers the ballast bed to its original height
Data Source
Figure 1
Figure 2
AI summary
A method for cleaning a ballast bed (4) of a track (2) by means of track-bound machines (8, 18, 21), wherein, by means of a cleaning machine (8), a ballast (1) situated under a track grid (5) is removed with a ballast removal apparatus (10), wherein, behind it, with respect to a working direction (12), cleaned and/or new ballast (1) is introduced into the track (2) in a plurality of layers by means of a ballast introduction apparatus (11) and a ballast train (15) and wherein the introduced ballast (1) is compacted by means of a tamping machine (18) and a stabilizing machine (21), wherein all the layers of the new and/or cleaned ballast (1) are introduced before a first tamping operation by means of the ballast introduction apparatus (11) and the ballast train (15), wherein the ballast bed (4) is compacted by means of a deep tamping unit (22) in different depth layers during the first tamping operation, wherein subsequently the track (2) is stabilized by means of the stabilizing machine, wherein directly thereafter the track grid (5) is tamped by means of the same or a further tamping machine (18) in a second tamping operation in only one depth layer, and wherein, after the second tamping operation, the track (2) is stabilized with the same or a further stabilizing machine (21).