Rail Clip Shoulder Design for Reduced Size and Cost
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Solution Overview
Problem
The existing rail fastening systems with concrete ties face challenges in reducing costs while maintaining high clamping forces, as the large size of support shoulders required for preloaded clips increases their cost and complexity, and the assembly process is cumbersome due to the need for manual placement of insulators.
Innovation Solution
A rail clip shoulder design with a reduced size that includes a rail face with a clip gateway, a ramp, and downwardly inclined loading surfaces, allowing for additional travel distance without increasing shoulder length, and featuring bifurcated arms for the toe section to distribute forces effectively, enabling easier assembly and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the support shoulder is made large to reduce the force needed to apply clips, then the ease of operation improves, but the cost and size of the support shoulder increases
Solution Approach 1:
The support shoulder is divided into distinct functional zones: a loading surface with inclined planes for force application, a ramp portion for clip travel, and a gateway portion for final positioning. This segmentation allows each zone to be optimized independently, reducing the overall size while maintaining operational effectiveness.
Solution Approach 2:
The invention utilizes the vertical dimension by creating inclined loading surfaces and ramps that allow the clip to travel downward into the support shoulder. This vertical travel component reduces the required horizontal length of the support shoulder, effectively reducing its overall size while maintaining the necessary travel distance for clip application.
2Adaptability or versatility
If the support shoulder is made large to accommodate preloaded clips, then the adaptability improves, but the cost and size increases
Solution Approach 1:
The support shoulder geometry is designed to automatically guide and position the clip during the loading process. The inclined loading surfaces and ramp structure perform the preliminary positioning action, allowing the clip to be preloaded without requiring additional travel distance or larger shoulder dimensions.
Solution Approach 2:
The invention changes the geometric parameters of the support shoulder, specifically the angles and dimensions of the loading surface and ramp portions. By optimizing these parameters, the shoulder can accommodate preloaded clips with reduced overall size, as the clip travels a more efficient path through the modified geometry.
3Manufacturing precision
If manual placement of insulators is required, then the manufacturing precision can be maintained, but the productivity decreases
Solution Approach 1:
The insulator is designed to self-position within the support shoulder during the clip installation process. The clip installation action automatically guides the insulator into its correct position, eliminating the need for separate manual placement while maintaining positioning accuracy. The system serves itself by using the clip installation process to simultaneously position both the clip and insulator.
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 design achieves high clamping forces of at least 8 kilonewtons with reduced shoulder size and cost, facilitating easier assembly and maintaining performance by transferring forces efficiently from the concrete to the metal support shoulder during clip application.
Implementation Method 1
The rail clip applies a high clamping force of 8 to 13 kilonewtons and this force is achieved by gradually displacing the toe of the clip from the base by driving the clip horizontally along a loading surface in the support shoulder
Implementation Method 2
The force required to fit the clip is usually inversely linked to the length the clip travels within the shoulder. Thus the support shoulders are usually large to reduce the force needed to apply the clips
Data Source
AI summary
Improved rail clip support shoulders are less expensive than conventional shoulders. The rail seat includes a concrete rail tie; a pair of rail clip support shoulders cast in place in said rail tie each said shoulder having a rail face between its external sides; a pair of shoulder insulators each shaped to lie against the rail face of the rail shoulder; a pair of rail clips each having a base section adapted to seat within the rail clip support shoulder and a toe section adapted to seat on the rail base, the toe section comprising a pair of bifurcated arms extending from said base section and being bent in a curve so that the toes lie adjacent but beyond the base; the arrangement being such that the clamping force exerted by each installed clip is at least 8 kilonewtons and the leading edge of the base section of the rail clip first engages a loading incline on either side of the rail clip ramp, while the line of contact of the trailing edge of base section is on the concrete rail tie and the trailing edge does not contact the rail clip ramp in the support shoulder until at least 40% of the distance to fully install the clamp has been traveled.