Rail Fastening Element for Fixed Slab Track Installation
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Solution Overview
Problem
Existing fixed slab track installation methods face challenges in achieving high accuracy and rapid installation, with top-down methods requiring precise and time-consuming underpouring of concrete and bottom-up methods being imprecise and lacking subsequent positional adjustments.
Innovation Solution
A rail fastening element system that combines bottom-up and top-down construction principles, where a base layer is set up with large tolerances, support elements are mounted with minimal dimensional accuracy, and rail fastening elements are inserted and secured with a hardening sealing compound, allowing for high accuracy and rapid track completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If top-down installation method is used with precise orientation of sleeper framework, then track position accuracy is improved, but installation time increases due to massive rough working steps and concrete underpouring requirements
Solution Approach 1:
The patent divides the fastening system into modular components: a mounting base body that interfaces with the support element, and a separate rail holder assembly. This segmentation allows each component to be manufactured and positioned independently with standard tolerances, eliminating the need for massive concrete underpouring while maintaining overall track accuracy through the interface design between segments.
Solution Approach 2:
The patent introduces a mounting base body as an intermediary component between the support element and the rail holder. This intermediary absorbs positioning tolerances and provides a stable interface that ensures accurate track position without requiring precise orientation of the entire sleeper framework, thereby reducing installation time while maintaining accuracy.
2Productivity
If bottom-up installation method is used with step-by-step construction, then installation speed and mechanization are improved, but track position accuracy deteriorates due to cumulative tolerances
Solution Approach 1:
The patent applies local quality by ensuring that only the critical interface surfaces between the mounting base body and the rail holder assembly require high precision, while other portions of the components can be manufactured with standard tolerances. This allows bottom-up installation with mechanization to proceed efficiently while maintaining track position accuracy at the critical fastening locations.
3Stability of the object's composition
If concrete underpouring is used to secure sleeper framework, then structural stability is improved, but material cost and installation complexity increase
Solution Approach 1:
The patent incorporates anchoring features and mounting structures into the mounting base body and support elements during prefabrication. This preliminary action eliminates the need for subsequent concrete underpouring operations, as the components are designed to be directly secured to one another, thereby reducing both material usage and installation complexity while maintaining structural stability.
4Adaptability or versatility
If subsequent positional adjustment of running rails is required, then adaptability is improved, but installation complexity and time increase due to repeated adjustments
Solution Approach 1:
The patent incorporates adjustable elements within the rail holder assembly that allow for controlled positional adjustments after initial installation. These dynamic adjustment mechanisms enable fine-tuning of rail position without requiring complete disassembly or repeated major adjustments, thereby providing adaptability while minimizing installation and adjustment time.
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
Enables simple, rapid, and accurate installation of fixed slab tracks with reduced material usage and cost, allowing for quick track usability and efficient dissipation of transverse forces from rail vehicles.
Implementation Method 1
a multiplicity of rail fastening elements according to the invention are inserted from above into the cut-outs and are locked by introduction of a hardening sealing compound into the intermediate spaces which remain between the rail fastening elements and the support elements
Data Source
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AI summary
The invention proposes a novel design for a fixed slab track (10) for rail vehicles, in which fixed slab track (10) a base layer (12), preferably made from asphalt, is placed on an underlying substrate (11), and a multiplicity of support elements are placed on the base layer, which support elements have in each case at least one cut-out on their upper side. Whereas the base layer and the support elements are set up from the bottom to the top (bottom-up) and large tolerances are acceptable in the process, rail fastening elements (20) are inserted in the subsequent method step into the cut-outs (17) in the support elements (13) from the top (top-down) and, after their vertical and lateral orientation, are locked by means of a hardening sealing compound (22). Here, the sealing compound is preferably filled in through at least one filling channel (38) which penetrates the rail fastening element vertically, and fills the cut-out (17) which is situated below the respective rail fastening element and the gap (46) which remains after the orientation between the support element and the rail fastening element, the material requirement for sealing compound being low overall.