Rail Decontamination Machine Subgrade Homogenization
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Solution Overview
Problem
Existing track rehabilitation machines face limitations in achieving consistent load-bearing capacity and speed due to quality fluctuations in excavated subgrade protection layer materials, which vary significantly along the track length.
Innovation Solution
A track rehabilitation machine with upstream processing units for homogenizing excavated formation protection layer materials through screening, crushing, and mixing with a liquid processing fluid, ensuring a consistent quality of the new subgrade protection layer, and utilizing multiple excavation chains for selective excavation and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the excavated formation protection layer is processed by mixing with solid materials such as clay, gypsum or lime, then the material can be introduced as a new PSS into the track, but sufficient load-bearing capacity, especially with regard to dynamic loads, is not achieved
Solution Approach 1:
The patent changes the fundamental parameter of the processing approach by replacing chemical mixing with mechanical processing. Instead of mixing excavated PSS with binders like clay, gypsum or lime, the invention uses mechanical crushing and screening to process the material, thereby achieving sufficient load-bearing capacity for dynamic loads while maintaining ease of manufacture.
Solution Approach 2:
The patent replaces the chemical/organic processing system (mixing with binders) with a mechanical processing system (crushing and screening). This substitution resolves the contradiction by achieving reliable load-bearing capacity through mechanical size reduction and fractionation without requiring additional binding materials.
2Productivity
If the track path rehabilitation is carried out at high speed, then the downtime of the track is reduced, but the quality consistency of the processed formation protection layer becomes difficult to maintain
Solution Approach 1:
The patent applies segmentation by dividing the formation protection layer into different size fractions through screening. The processing system separates the material into distinct grain size categories, ensuring that each fraction meets consistent quality requirements. This segmentation approach maintains manufacturing precision even at high rehabilitation speeds by providing clear separation criteria for material quality control.
Solution Approach 2:
The patent changes the processing parameters by using mechanical crushing and screening instead of chemical mixing. This approach provides more controllable and consistent processing parameters that can be maintained at high speeds, ensuring uniform material quality throughout the rehabilitation process without the variability introduced by chemical binder mixing.
3Productivity
If multiple excavation chains are used to excavate the track substructure, then the rehabilitation efficiency is improved, but the complexity of the machine increases
Solution Approach 1:
The patent applies universality by designing the excavation chains to perform multiple functions. The same excavation chains that remove the formation protection layer also process and prepare the material for recycling. This multi-functionality increases rehabilitation efficiency without proportionally increasing machine complexity, as the chains serve both excavation and initial processing roles.
Solution Approach 2:
The patent merges the excavation function with the processing function into a unified system. The excavation chains are integrated with the screening and processing mechanisms, combining what could be separate operations into a single coordinated system. This merging reduces overall machine complexity while maintaining high rehabilitation efficiency.
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 enables efficient and consistent preparation of the subgrade protection layer, ensuring high load-bearing capacity and speed, even with varying geological conditions, by providing a homogeneous material mix and reducing material transportation needs.
Implementation Method 1
a screening device for screening out coarse components from the excavated formation protection layer
Implementation Method 2
a crusher for crushing the screened-out coarse components from the excavated formation protection layer
Implementation Method 3
a mixing device for mixing the processed formation protection layer material with a liquid processing fluid
Data Source
Figure 1
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Figure 3
AI summary
The machine has a formation protective layer conditioning unit (60) with a mixing device for mixing the layer with liquid treatment fluid. An old formation protective layer conveying device (52) conveys the partially conditioned layer from another formation protective layer conditioning unit to the former conditioning unit. A delivery line (71) conveys the fluid from a fluid tank unit to the mixing device, and a formation protective layer introducing device (100) introduces a new formation protective layer. A ballast introduction device introduces a ballast layer on an interlayer.