Magnetic Holding System for Prestressed Concrete Sleeper Production
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Solution Overview
Problem
The existing methods for producing prestressed concrete sleepers and switch sleepers face challenges in accurately positioning and securely fixing built-in parts for rail fastening, especially with varying geometries and positions, which requires frequent changes in formwork matrices and increases the risk of cracking and operational inefficiencies.
Innovation Solution
The method employs a mold bed with permanent-magnetic holding devices to precisely fix fastening devices or built-in parts, allowing for flexible production of sleepers of different lengths and geometries without the need for frequent changes in formwork, using switchable permanent magnets to secure and release the beaded plates during the concrete hardening process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening methods (welding, gluing) are used to fix built-in parts in formwork, then the built-in parts can be securely fixed, but additional work is required to remove adhesive residues or welded connection residues from the fastening devices
Solution Approach 1:
The patent replaces mechanical/chemical connection methods (welding, gluing) with a magnetic field-based holding system. Permanent magnets embedded in the formwork base provide holding force without requiring adhesive or welded connections, thereby eliminating residue removal work while maintaining secure fixation of the built-in parts.
Solution Approach 2:
The patent introduces permanent magnets as an intermediary between the formwork base and the built-in parts. These magnets provide the holding function without directly connecting to the fastening devices, allowing the devices to be removed cleanly without residue removal work.
2Manufacturing precision
If matrices with differently arranged bores are used for different switch sleeper positions, then accurate positioning of built-in parts is achieved, but a large number of matrices must be kept available or new bores must be produced for each case
Solution Approach 1:
The patent makes the formwork base universal by embedding multiple permanent magnets at various positions in the base. This allows the same base to accommodate built-in parts at different locations and orientations by simply moving the parts to different magnetic holding positions, eliminating the need for multiple specialized matrices.
Solution Approach 2:
The patent transforms the static, fixed-bore matrices into a dynamic system where the magnetic holding positions can adapt to different requirements. The permanent magnets provide flexible positioning capability, allowing the formwork to be reconfigured for different switch sleeper types without physical changes to the base structure.
3Reliability
If blind rivets are used to anchor fastening means through bores in the formwork base, then the built-in parts can be temporarily fixed, but the necessity remains of having to arrange bores at different points for each individual switch sleeper
Solution Approach 1:
The patent replaces the mechanical blind rivet anchoring system with a magnetic field-based holding system. The permanent magnets provide the necessary holding force to temporarily fix the built-in parts without requiring physical bores or rivets, thereby enabling flexible positioning for different sleeper types using the same formwork base.
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 approach minimizes the risk of cracking and allows for efficient, flexible production of prestressed concrete parts with reduced personnel effort and material requirements, enabling automatic setting of fastening devices and eliminating the need for complex mold conversions.
Implementation Method 1
at least one permanent magnet is provided in the mold bed or in the mold trough or below the mold trough in order to detachably fix the holding device and/or the mold body
Data Source
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AI summary
The invention relates to a method and a device for manufacturing prestressed concrete precast elements, which have cast-in or molded-in fastening devices (5) or embedded components, in particular prestressed concrete sleepers or prestressed concrete turnout sleepers with means for rail fastening, wherein molded parts are produced by casting in at least one mold bed (1) and the mold bed (1) accommodates a plurality of prestressing steel bars (18), furthermore, holding boxes or holding plates (6) are inserted or provided between the molded parts and/or in the end regions (6, 13) of the mold bed (1), and the molded parts are removed from the respective mold bed as the concrete hardens. According to the invention, free bottom plates (2) are inserted in the mold bed (1) for fastening devices or embedded components, or mold beds provided with such bottom plates are used.Depending on the desired length dimensions of the molded part, the storage boxes or the storage plates (6) are positioned and the fastening device (3) or installation components are precisely fixed to the respective base plate (2) by means of permanent magnetic holding devices (10). In a preferred embodiment of the invention, switchable permanent magnets are used.