Movable Frog Point Wing Rail Metal-Forming
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Solution Overview
Problem
Existing switch designs require separate rail profiles and connection welds for wing rails, which increase complexity and maintenance, especially in high-speed applications where stability and uniform wear are critical.
Innovation Solution
The wing rails are designed as Vignol rails with a lower rail profile produced by metal-forming from a single piece, eliminating the need for separate rail profiles and connection welds, and are supported by screws with tapered webs to maintain stability and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If separate rail profiles and connection welds are used for wing rails, then the lower rail profile can be achieved, but the device complexity and maintenance needs increase
Solution Approach 1:
The patent merges the wing rail profile change into a single continuous rail structure by applying metal-forming techniques directly to the Vignol rail. This eliminates the need for separate rail profiles and connection welds, reducing device complexity while maintaining the required lower profile shape in the frog point region
Solution Approach 2:
The patent applies metal-forming processes to locally modify the rail profile parameters of the Vignol wing rail. By changing the geometric parameters (height, cross-section) through controlled plastic deformation, the desired lower profile is achieved without requiring separate components or welds
2Shape
If connection welds are used for wing rails, then the lower rail profile can be achieved, but thermal changes and textural changes in the rail head occur
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical metal-forming process. Instead of using heat to join separate rail profiles, the invention uses controlled plastic deformation to create the lower profile directly on the Vignol rail, thereby eliminating thermal changes and associated textural changes in the rail head
3Shape
If add-on pieces are used for wing rails, then the lower rail profile can be achieved, but uniform running behavior is compromised
Solution Approach 1:
The patent combines the entire wing rail as a single continuous Vignol rail structure with a locally formed lower profile. This eliminates add-on pieces and ensures uniform material properties and running behavior throughout the rail, while still achieving the required lower profile shape in the frog point region through metal-forming
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 configuration reduces thermal changes and maintenance needs, ensures uniform running behavior, and enhances stability by eliminating add-on pieces, while allowing for flexible adaptation to the frog point's movement without ascension risks.
Implementation Method 1
the wing rails are designed as Vignol rails whose region configured with a lower rail profile is produced by metal-forming departing from the Vignol rail profile
Implementation Method 2
Metal-forming in this case is preferably performed after preheating to about 900°
Data Source
AI summary
In a switch including a switch frog (1) with a movable frog point (2) and wing rails (5, 6), wherein the wing rails (5, 6) in the region of the frog point (2) each have a rail profile which is lower than that of a standard rail, the wing rails (5, 6) are designed as Vignol rails whose region configured with a lower rail profile is produced by metal-forming departing from the Vignol rail profile.