Ballast Renewal Machine with Front Rear Screening and Flow Distribution
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Solution Overview
Problem
Existing machines for repairing railway ballast beds are inefficient due to limited compactness, excessive conveyor capacity, and lack of storage for purified ballast, leading to logistical challenges and insufficient ballast supply during initial and final phases of operation.
Innovation Solution
A machine design with a distributor that splits the ballast flow into two separate streams, allowing for side-by-side positioning of screening machines, with adjustable flow control and modular components including a ballast tank for storage and flexible conveyor systems to manage ballast distribution and storage efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If two screening machines are positioned side by side behind the ballast cleaner, then the size of the screening machines is reduced, but the machine is no more compact than one equipped with a single screening machine and requires a long transport route for excavated material
Solution Approach 1:
The patent inverts the conventional arrangement by positioning the front screening machine ahead of the ballast cleaner and the rear screening machine behind it, rather than placing both behind. This inversion creates a compact configuration where the front screening machine processes material immediately upon excavation, eliminating the need for a long transport route to the front of the vehicle while still providing rear screening capacity.
Solution Approach 2:
The patent segments the screening function into two spatially separated machines operating at different locations relative to the ballast cleaner. The front screening machine handles material flow in one direction while the rear screening machine handles material flow in the opposite direction, allowing each machine to be smaller while collectively processing the entire ballast stream.
2Productivity
If two screening machines are positioned side by side, then screening capacity is increased, but the machine requires a high-capacity conveyor to transport ballast from the ballast cleaner to the screening machines
Solution Approach 1:
The patent divides the ballast flow into two separate streams using a distributor, with one stream going to the front screening machine and the other to the rear screening machine. This segmentation allows each screening machine to receive a portion of the total flow, reducing the capacity requirements of individual conveyors while maintaining overall screening capacity.
Solution Approach 2:
The patent transitions from a single-line sequential processing arrangement to a two-dimensional parallel arrangement with front and rear screening machines operating simultaneously. This dimensional change allows the system to handle the same total ballast volume with smaller individual conveyors by utilizing both spatial directions.
3Device complexity
If there is no provision for storing cleaned ballast, then the machine structure is simplified, but there is no storage for excess cleaned ballast resulting from the screening process
Solution Approach 1:
The patent designs the rear screening machine's output to serve multiple functions: it can supply cleaned ballast to the rear rebalancing plow for immediate use, or excess cleaned ballast can be stored in the ballast tank for later use. This multi-functionality allows the same structural element to handle both immediate processing needs and storage requirements.
Solution Approach 2:
The patent incorporates a ballast tank positioned to receive excess cleaned ballast from the rear screening machine as a preliminary storage measure. This preliminary action allows the system to store cleaned ballast before it is needed, enabling the machine to operate efficiently during initial and final phases when ballast supply requirements differ from normal operation.
4Device complexity
If there is no provision for a route to bring in new ballast, then the machine structure is simplified, but there is no way to bring in new ballast when cleaned ballast is insufficient
Solution Approach 1:
The patent designs the ballast tank to serve multiple purposes: it stores excess cleaned ballast from the rear screening machine during normal operation, and simultaneously serves as a source for supplying new ballast to the front screening machine or rear rebalancing plow when cleaned ballast is insufficient. This multi-functionality provides flexibility without requiring separate dedicated routes.
Data Source
Figure 1A~1C
Figure 2A~2C
AI summary
A machine (10) for repairing a ballast bed (12) comprises an undercutter (26) that defines a direction of movement (16) of the repairing machine (10), a distributor (28) for dividing a flow of ballast entering from the undercutter (26) into a rear flow of exiting ballast and a separate front flow of exiting ballast; at least one rear screening machine (36) positioned behind the undercutter (26) in the direction of movement and fed by the rear flow of exiting ballst; and at least one front screening machine (30) positioned in front of the undercutter (26) and fed by the front flow of exiting ballast, the distributor (28) having a variator for varying the ratio between the separate first and the second flows of exiting ballast.