Composite Rail Profile With Insert Rods For Welded Bonding
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Solution Overview
Problem
Existing composite conductor rails with a light metal carrier and a harder metal profile strip suffer from long-term detachment under high loads due to inadequate bonding, leading to surface undulations and mechanical instability, particularly when used for electrifying rail vehicles.
Innovation Solution
A composite profile design featuring a rail-like carrier profile extruded from light metal with a channel-like profile strip of harder metal, where insert rods parallel to the profile strip's longitudinal axis engage in lateral slots of the carrier profile, forming a force-fit or form-fit connection, and are welded under mechanical prestressing to ensure a secure bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an intimate metallic bond is formed between the carrier profile and profile strip during extrusion, then the connection strength is improved, but the profile strip comes away from the carrier profile in the long term under high load
Solution Approach 1:
The connection system is segmented into three distinct components: the carrier profile, the profile strip, and intermediate insert rods. The insert rods act as separate anchoring elements that penetrate into the carrier profile and are welded to the profile strip, creating a multi-stage connection system rather than relying on a single intimate metallic bond. This segmentation allows each component to perform its specific function: insert rods provide mechanical anchoring and welding surfaces, while the profile strip maintains electrical contact.
Solution Approach 2:
The invention employs a composite connection structure combining different materials and bonding mechanisms. The insert rods are made of a material compatible with both the light metal carrier profile and the harder metal profile strip. The connection system integrates mechanical insertion (force-fit), metallurgical bonding (welding), and frictional contact, creating a composite connection system that leverages the advantages of multiple bonding mechanisms to achieve both strength and long-term reliability.
2Strength
If the profile strip is pressed or caulked into the carrier profile in stages, then the connection is strengthened, but undulations are created on the surface of the covering profile
Solution Approach 1:
The insert rods are pre-positioned within the carrier profile before the profile strip is installed. The carrier profile is extruded with pre-formed insertion slots or recesses that accommodate the insert rods. This preliminary preparation eliminates the need for subsequent pressing or caulk ing operations that would distort the profile strip surface. The insert rods are already in their final positions, ready to receive the profile strip and provide immediate anchoring without requiring deformation of the covering profile.
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 uniformly good contact resistance and uniform current collection over the steel surface, prevents sliding due to thermal stresses, and maintains mechanical stability even under wear, while allowing for economical manufacturing without significant upgrades to existing extrusion equipment.
Implementation Method 1
are welded under mechanical prestressing to ensure a secure bond
Implementation Method 2
the carrier profile and profile strip being joined together in force-fit and/or form-fit relationship
Data Source
AI summary
A composite profile comprising an extruded aluminum alloy carrier profile comprising a rail head having a longitudinal axis B, the rail head comprises a surface and two longitudinal edges extending parallel to the longitudinal axis B and a metal channel shaped profile strip comprising a base portion spanning the surface of the rail head and parallel side legs which lie on the longitudinal edges of the head rail, an insert rod is provided on the parallel side legs which lie on the longitudinal edges of the head rail and engage in lateral slots provided in the two longitudinal edges of the rail head, wherein the profile strip is attached to the carrier profile under mechanical pretension by way of a weld seam which contacts the rail head of the extruded aluminum alloy carrier profile.