Laser-guided pad positioning for railway sleeper casting
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Solution Overview
Problem
Existing methods for applying rubber pads to concrete railway sleepers face instability due to variations in concrete level, leading to uneven connections and compromised vibration absorption.
Innovation Solution
An apparatus with contactless sensors and adjustable positioning mechanisms ensures precise placement of pads relative to the concrete surface, using laser distance measurement and motorized hoists to maintain correct positioning and alignment, even with imperfect concrete leveling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the pad is positioned at a predetermined height above the tank, then the positioning process is simple, but the connection stability deteriorates due to concrete level variations
Solution Approach 1:
The system employs sensors to detect the actual concrete level and feeds this information back to the positioning mechanism. The positioning means adjusts the pad height based on the detected concrete level, creating a closed-loop control system that maintains reliable connection despite variations in concrete dosing or leveling.
Solution Approach 2:
The pad positioning system transitions from a static predetermined height to a dynamic adjustable position. The positioning means can move the pad vertically to match the actual concrete level, allowing the system to adapt to variations in concrete level while maintaining simple operation through automated adjustment.
2Adaptability or versatility
If the concrete level is allowed to vary, then the manufacturing process is more flexible, but the pad connection precision deteriorates
Solution Approach 1:
The system changes the positioning parameter of the pad based on the detected concrete level. By adjusting the pad height parameter dynamically according to the actual concrete level, the system maintains connection precision while allowing flexibility in concrete dosing and leveling processes.
Solution Approach 2:
The sensor-based feedback mechanism detects concrete level variations and automatically adjusts pad positioning to compensate. This allows the concrete level to vary within certain limits while maintaining precise pad-concrete connection, effectively decoupling the two parameters.
3Device complexity
If manual positioning methods are used, then the device complexity is low, but the measurement and detection capability deteriorates
Solution Approach 1:
The system replaces manual mechanical measurement with sensor-based detection. Sensors automatically measure the concrete level and provide data to the positioning means, eliminating the need for complex manual measurement procedures while achieving high measurement precision with relatively simple device architecture.
Solution Approach 2:
The positioning system performs self-adjustment by automatically detecting concrete level and positioning the pad accordingly. This self-service capability eliminates the need for complex external measurement and adjustment systems, achieving both low device complexity and high measurement precision.
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
Ensures a stable and uniform connection of pads to the sleepers, enhancing vibration absorption and sleeper positioning, regardless of concrete level variations during the casting process.
Implementation Method 1
The apparatus (1) comprises a sensor (30) suitable for measuring a distance to a point of a free surface of the concrete
Data Source
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AI summary
An apparatus (1) for application of a pad (92) to a base of a railway sleeper made of concrete, said apparatus comprising: - a form (2) in turn comprising at least a first tank (21) intended to receive a cast of concrete to form the sleeper; - means (3) for detecting a parameter associated to a vertical component of a distance between at least one predetermined point and at least a point of the free surface of the concrete located in the first tank (21) of the form (2), preferably a laser measuring system (31); - means (4) for positioning the pad (92) in the first tank (21) at a height that is a function of an input coming from the detection means (3).The positioning means (4) suitably comprise pad gripping means (5), e.g. suction cups, which can adjust the inclination of the rubber pad (92) with respect to a horizontal plane.