Boltless Rail Brace Wedge Clamping Mechanism
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Solution Overview
Problem
Existing boltless rail brace assemblies face issues with maintaining a constant load on the brace, leading to potential loosening under excessive loads, and require complex installation processes, especially in applications where only one side of the rail is braced, such as switches and curves.
Innovation Solution
A rail brace assembly that uses a wedge to apply an upward force on the brace, translating it into a rotational force and a downward force on the rail base for secure clamping, eliminating the need for a spring clip to directly bear on the brace, and allowing for a universal configuration adaptable to various rail sections with optional resilient elements for managing lateral loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring clip is used to bear directly on the brace to maintain load, then the brace can be secured, but the system becomes more complex and the spring clip may not provide sufficient centralized force
Solution Approach 1:
The invention extracts the spring clip from direct contact with the brace, removing it from the primary load-bearing path. The spring clip is retained only for lateral retention, while the wedge independently provides the downward clamping force through mechanical advantage, simplifying the load transmission path and reducing system complexity.
Solution Approach 2:
The invention introduces a wedge as an intermediary mechanical element between the tie plate and the brace. This wedge translates vertical clamping force into a downward force on the rail base through rotational leverage, providing more reliable and centralized force application without requiring the spring clip to bear directly on the brace.
2Stability of the object's composition
If the downward force is applied from the distal side of the cover block (as in Farrell et al.), then the wedge fit is secure, but the force is removed from the brace and may not provide sufficient restraining force
Solution Approach 1:
The invention changes the dimensional approach by applying force at a different location - the nose of the wedge contacts the rail base at a point closer to the rail, while the clamping force is applied at the distal end. This creates a lever arm that provides both secure wedge fit and sufficient restraining force on the rail through rotational mechanics.
3Reliability
If bolted brace assemblies are used, then the brace is securely fastened, but the manufacturing, installation and maintenance costs increase
Solution Approach 1:
The invention replaces the bolted mechanical fastening system with a wedge-based mechanical advantage system. The wedge utilizes friction and leverage to secure the brace without requiring through-bolts, eliminating the need for holes through the tie plate and reducing both manufacturing complexity and installation time while maintaining secure fastening.
4Ease of operation
If a boltless friction fit brace is used, then installation is simplified, but the brace may loosen under excessive loads
Solution Approach 1:
The invention introduces dynamic elements including a resilient member that provides elastic compression and a wedge that can be adjusted or replaced. These dynamic components allow the system to maintain friction fit simplicity while adapting to load conditions, preventing loosening under excessive loads through elastic recovery and adjustable mechanical advantage.
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 solution provides a stronger, more secure rail bracing system that maintains constant clamping force without relying on spring clips, simplifies installation, and is adaptable to different rail sections, effectively managing lateral and rollover forces from passing trains.
Implementation Method 1
A wedge slides between an upper surface of the base block and an underside of the brace, applying an upward force on the brace. The upward force is translated into a rotational force around the interlock between the brace and base block and results in a downward force being applied to the rail base to hold it in place.
Implementation Method 2
An optional spring clip may be used to exert force on the wedge or on an optional washer and maintain the adjustment of the brace, but the spring clip does not bear directly down on the brace.
Implementation Method 3
The dimensions of the brace are tapered, allowing the brace to be tightly wedged between the rail and the stop block. Rollover and lateral forces from passing trains are resisted by the abutment of the brace and the stop block, and downward force of the spring clip on the toe of the brace.
Data Source
AI summary
A boltless brace assembly for a rail includes a base block interlocked with a brace, and further includes a wedge to be inserted between an upper surface of the base block and a lower surface of the brace, thereby applying an upward force to the brace and a resultant downward force to secure the rail base. The brace assembly may be modified to provide a universal brace assembly, a resilient brace assembly, or a frog base clamp.