Ballast Cleaning System With Mechanical Screening
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Solution Overview
Problem
Current ballast cleaning systems require large amounts of water for washing and struggle with efficient separation of overburden from gravel, leading to high operational costs and inefficiencies.
Innovation Solution
A system with an endless clearing chain, multiple conveyor devices, and a second screening system with rotating screening elements for fine screening, along with a processing unit and separate screening vehicle, allows for direct transport and efficient separation of gravel and overburden, reducing water usage and enhancing conveying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a washing plant with water supply is used for ballast cleaning, then the ballast can be cleaned effectively, but large quantities of water are needed which increases operational costs
Solution Approach 1:
The invention extracts the water washing function from the ballast cleaning system and replaces it with a purely mechanical processing approach. The ballast is cleaned through crushing and screening operations that separate contaminants without requiring water, thereby eliminating the harmful water consumption while maintaining cleaning effectiveness
Solution Approach 2:
The invention replaces the hydraulic/water-based cleaning system with a mechanical processing system consisting of crushers and screening plants. The mechanical forces of crushing and the physical separation through screens achieve the cleaning function that previously required water washing
2Device complexity
If a single screening plant is used after ballast processing, then the system is simpler, but overburden separation from sharpened gravel is insufficient
Solution Approach 1:
The screening function is segmented into two distinct stages: a first screening plant that performs initial separation after ballast processing, and a second screening plant that performs fine separation to completely separate overburden from sharpened gravel. This segmentation allows each screen to be optimized for its specific separation task, achieving high separation quality
Solution Approach 2:
The first screening plant acts as an intermediary between the crusher and the second screening plant. It performs preliminary separation that prepares the material for the final fine separation in the second screening plant, creating a staged purification process that achieves complete overburden removal
3Manufacturing precision
If ballast is transported through multiple processing stages, then cleaning quality improves, but transport time and system complexity increase
Solution Approach 1:
The invention implements continuous ballast processing through the entire system. The clearing chain continuously feeds ballast to the crusher, which continuously processes and delivers it to the screening plants. The screened ballast is continuously conveyed back to the track. This continuous operation eliminates idle time between processing stages while maintaining high cleaning quality through the multi-stage process
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
The system enables efficient and cost-effective cleaning and separation of ballast, minimizing water consumption and improving the quality of the cleaned gravel for reintroduction into the track bed.
Implementation Method 1
a second screening plant for fine screening of the sharpened gravel, with the screen deck being designed, for example, as a roller screen
Implementation Method 2
Furthermore, it is advantageous to equip the screen deck with a vibration drive. This allows for a further increase in conveying capacity by subjecting the screen deck to linear vibration.
Implementation Method 3
a processing unit including a crusher, a first screening plant
Data Source
AI summary
The invention relates to a system (1) for cleaning ballast (2) of a track (3), said system consisting of a plurality of vehicles (6) having machine frames (5) supported on rail bogies (4). The system (1) comprises an endless clearing chain (8) which is guided around the track (3) for collecting the ballast (2) lying under the track (3), a processing unit (9) having a crusher (15), a first screening unit (10), a second screening unit (11), conveying devices (13, 16, 17, 18, 22) for transporting ballast (2) and a ballast introduction device (12). A first conveying device (13) for transporting ballast (2) to the processing unit (9) is associated with the endless clearing chain (8). A second conveying device (16) for transporting ballast (2) to the first screening unit (10) is associated with the processing unit (9). A third conveying device (17) for transporting ballast (2) to the second screening unit (11) is associated with the first screening unit (10).