Rail Conductor Assembly With Single Exothermic Weld Footprint
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Solution Overview
Problem
The challenge in railroad systems is to securely connect conductors to rails while minimizing the number of electrical connection points to prevent metal fatigue, thermal damage, and accidental removal, especially in confined spaces with limited room for multiple connections.
Innovation Solution
A conductor assembly featuring a single connecting conductor exothermically welded to multiple extending conductors at a common weld structure, allowing for secure attachment to the rail with a reduced footprint, reducing the likelihood of removal by passing vehicles and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple conductors are connected directly to the rail at separate connection points, then each conductor can be securely attached, but the number of connection points increases leading to metal fatigue, thermal damage, and accidental removal
Solution Approach 1:
The patent combines multiple conductor connections into a single connection point by welding a conductor assembly (containing multiple conductors) to the rail at one location. This merging approach reduces the number of separate connection points from multiple individual connections to a single consolidated connection, thereby preventing metal fatigue and thermal damage that would result from multiple separate welds or mechanical connections.
Solution Approach 2:
The conductor assembly serves multiple functions simultaneously: it provides electrical connections for multiple track circuits, switches, or signals while requiring only a single attachment point to the rail. The assembly acts as a universal interface that consolidates what would otherwise require multiple separate connection devices, reducing the overall number of connection points while maintaining all necessary electrical connections.
2Ease of operation
If multiple conductors are connected at separate locations on the rail, then each connection can be individually secured, but the footprint and space required on the rail increases
Solution Approach 1:
The patent merges multiple conductors into a single assembly that occupies a compact footprint on the rail. Instead of spreading multiple connection points across a large area of the rail, the entire multi-conductor assembly is welded at one location, significantly reducing the space required on the rail while maintaining installation flexibility.
Solution Approach 2:
The conductor assembly structure nests multiple conductors within a compact arrangement, allowing them to be bundled together and connected to the rail at a single point. This nesting approach enables multiple conductors to share the same spatial footprint on the rail, minimizing the area occupied while preserving the ability to individually access and connect each conductor to its destination.
3Strength
If conductors are connected with multiple connection points, then secure attachment is achieved, but the likelihood of accidental removal by passing vehicles and equipment increases
Solution Approach 1:
The patent combines multiple conductor attachments into a single robust weld connection. This consolidated connection point is stronger and more resistant to accidental removal by passing vehicles and equipment compared to multiple separate connections. The single weld creates a unified attachment that is less susceptible to disruption while maintaining secure attachment of all conductors in the assembly.
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 solution provides robust, adaptable connections that reduce the number of connection points, minimize thermal damage, and prevent accidental removal, thereby enhancing the integrity and operation of railroad rails while simplifying the installation process.
Implementation Method 1
An exothermic weld can connect a first end of the first conductor to first ends of the second conductors
Data Source
AI summary
A conductor assembly for a rail can include a first conductor and a plurality of second conductors (e.g., with each of the plurality of second conductors having a different length). An exothermic weld can connect a first end of the first conductor to first ends of the second conductors (e.g., three or more second conductors of different lengths).