Rail Fastening System Angled Guide Plate Assembly
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Solution Overview
Problem
Existing rail fastening systems face challenges in achieving simple, automated assembly adaptable to different rail types and ensuring high electrical resistance, especially on wet concrete sleepers.
Innovation Solution
The rail fastening system employs an angled guide plate with a tension clamp that can be moved from a pre-assembly to a final assembly position without loosening screws, utilizing a washer for prestressing and featuring a sealing and insulating element to maintain electrical insulation, and includes a wedge-shaped support for unevenness compensation and anti-tilt protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the tension clamp is designed to accommodate different rail types with different rail foot widths, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The tension clamp is designed with a universal structure that can accommodate different rail types (e.g., type U 50 and type UIC 60) with different rail foot widths using only one type of tension clamp, achieving multi-functionality without requiring multiple specialized components
Solution Approach 2:
The tension clamp features movable elements that can be adjusted to different positions to adapt to various rail foot widths, allowing the same clamp to serve multiple functions through dynamic reconfiguration rather than requiring multiple fixed designs
2Productivity
If the assembly process requires moving the tension clamp from pre-assembly to final assembly position without loosening the screw, then the productivity is improved, but the ease of operation deteriorates due to the need for precise positioning
Solution Approach 1:
The tension clamp is pre-assembled with the screw in a pre-assembly position where the screw is tightened with a torque of approx. 50 Nm, allowing the clamp to be easily handled and positioned before final installation, thereby simplifying the overall assembly process while maintaining high productivity
3Reliability
If the angled guide plate is designed to hold the tension clamp in both pre-assembly and final assembly positions, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The angled guide plate serves as an intermediary component that provides designated positions for the tension clamp during both pre-assembly and final assembly states, ensuring reliable positioning and guiding the assembly process without requiring complex mechanisms
4Reliability
If the sealing and insulating element is added to maintain electrical resistance in wet conditions, then the electrical resistance is improved, but the device complexity increases
Solution Approach 1:
A sealing and insulating element made of elastomeric material is integrated into the rail fastening system to provide both sealing against water ingress and electrical insulation in one composite component, maintaining high electrical resistance in wet conditions without requiring separate sealing and insulation elements
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 configuration allows for efficient, automated assembly of various rail types with enhanced electrical insulation and resistance, even in wet conditions, by using a sealing and insulating element and wedge-shaped support to prevent water ingress and maintain high electrical resistance.
Implementation Method 1
A sealing and insulating element arranged between the shank of the screw and the hollow cylindrical section
Implementation Method 2
the rail fastener achieves a high electrical resistance value. This is measured between the two rails on a wet concrete sleeper
Implementation Method 3
a non-positive, elastic fastening of a rail to a sleeper
Implementation Method 4
at least one tensioning clamp which, when assembled, is arranged between an angled guide plate and a screw
Implementation Method 5
The end of the preferably wedge-shaped support facing the rail can advantageously protrude beyond the foot of the rail by a predetermined height
Data Source
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AI summary
Rail fastening system (1) for the force-fit elastic fastening of a rail (2) to a sleeper (3) of a track system, comprising at least one angle guide plate (5) that can be fixed to the sleeper (3) by at least one screw (4) and at least one clamping clamp (6), wherein the angle guide plate (5) is designed to hold the clamping clamp (6) in a pre-assembly position (I) and in a final assembly position (II), wherein the clamping clamp (6) is pre-tensioned in the pre-assembly position (I) and in the final assembly position (II) by the head (7) of the at least one screw (4) directly or indirectly in the direction of the angle guide plate (5), wherein for the direct or indirect bearing of the head (7) of the screw (4) in the pre-assembly position (I) or final assembly position (II) a first ora second essentially flat support surface (8,9) is provided and wherein the plane of the first support surface (8) and the plane of the second support surface (9) are arranged pivoted relative to each other by an angle (α).