Rail Bed Refurbishing Machine with Onboard Material Processing
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Solution Overview
Problem
Existing track rehabilitation machines face limitations in working speed due to inefficiencies in processing and reusing excavated materials, particularly in achieving sufficient load-bearing capacity and quality of the formation protection layer, leading to increased maintenance and material costs.
Innovation Solution
A track rehabilitation machine equipped with dual excavation devices, multiple screening and crushing units, and a mixing system that processes and recycles ballast and formation protection layer materials to produce high-quality aggregates for reuse, optimizing material flow and reducing wear on processing units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the excavated old formation protection layer is processed by mixing with solid materials and reintroduced, then material reuse is achieved, but sufficient load-bearing capacity and dynamic load resistance are not achieved
Solution Approach 1:
The patent changes the physical-chemical parameters of the formation protection layer material through controlled mixing with binders and water, transforming the material properties to achieve both load-bearing capacity and drainage functionality. The mixing process modifies the material composition and structure to meet performance requirements.
Solution Approach 2:
The patent creates a composite material by combining excavated formation protection layer with binders and water, forming a mixed material that possesses both the drainage characteristics of the original material and the load-bearing capacity provided by the binder components.
2Productivity
If the track rehabilitation machine operates at high speed to reduce track downtime, then productivity increases, but the processing and removal of excavated materials becomes a limiting factor
Solution Approach 1:
The patent implements continuous processing of excavated materials through integrated screening, crushing, and mixing operations that occur without interruption during the track rehabilitation process. The mixed formation protection layer is continuously produced and reintroduced, eliminating idle time between excavation and material replacement.
Solution Approach 2:
The track rehabilitation machine processes its own excavated materials through onboard screening, crushing, and mixing equipment, eliminating the need for separate material removal and replacement operations. The machine transforms waste material into usable formation protection layer while moving along the track.
3Reliability
If a mechanical damping layer is introduced to improve load-bearing capacity, then dynamic load resistance increases, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent achieves improved load-bearing capacity by modifying the physical-chemical parameters of the formation protection layer itself through binder addition, rather than adding separate structural layers. This transforms the material properties to provide both damping and load-bearing functions within a single layer.
Solution Approach 2:
The mixed formation protection layer serves multiple functions simultaneously: it provides load-bearing capacity, drainage capability, and frost resistance, eliminating the need for separate specialized layers. The single mixed layer performs what would otherwise require multiple distinct structural components.
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 machine enables faster and more efficient track rehabilitation by ensuring consistent material quality and reduced maintenance, allowing for extensive reuse of excavated materials across varying soil types and compositions, thus enhancing load-bearing capacity and operational efficiency.
Implementation Method 1
a first screening device for separating of coarse fractions and fine fractions from the excavated PPS
Implementation Method 2
a crusher for breaking the coarse components screened therefrom into fractions
Implementation Method 3
a second PSS preparation unit for preparing the excavated formation protection layer, which has a mixing device for mixing the excavated PSS comprises a processing aggregate material
Data Source
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AI summary
The invention relates to a track rehabilitation machine designed to excavate old ballast and subgrade protection layer (PSS) and to install a new subgrade protection layer and a new ballast layer, wherein a first PSS processing unit is provided which includes a screening device for separating coarse and fine particles, a fraction conveying device for conveying the fractions from a crusher to the screening device, and a return conveying device for returning the coarse components screened out in the screening device to the crusher.