Rail Grinding Machine Pivotable Motor Frame and Liquid Cooling
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Solution Overview
Problem
Existing rail grinding machines lack the flexibility and precision to effectively process all points of the rail profile, particularly due to limitations in adjustability and dust protection for the electric motor, and require multiple machines for different tasks.
Innovation Solution
A manually operated grinding machine with a pivotable grinding unit mounted in a motor frame, adjustable in relation to a supporting frame, featuring liquid cooling for the electric motor, and a modular design allowing for various working positions and energy independence, enabling efficient processing of rail profiles with minimal equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the grinding unit is made fixed and non-adjustable, then the device complexity is reduced, but the manufacturing precision and adaptability to different rail profiles deteriorate
Solution Approach 1:
The grinding unit is made pivotable about a longitudinal axis extending in the direction of the track, allowing the grinding tool to be positioned at predetermined angles relative to the rail profile. This dynamic adjustment capability enables precise machining of different rail surfaces while maintaining manageable device complexity through controlled degrees of freedom.
Solution Approach 2:
The grinding machine is designed to process both sides of the rail profile using a single grinding unit that can pivot 180°. This multi-functional capability allows one device to perform multiple machining tasks on different rail surfaces, eliminating the need for separate fixed machines for each task.
2Device complexity
If the electric motor is exposed to grinding dust, then the device complexity is reduced, but the reliability of the electric motor deteriorates
Solution Approach 1:
The electric motor is encapsulated in a protective housing that seals the motor from grinding dust generated during operation. This flexible enclosure design protects the motor components while allowing for compact integration into the grinding unit without requiring complex cooling systems.
Solution Approach 2:
A liquid cooling system with heat exchanger and pump is implemented to cool the encapsulated electric motor. The liquid cooling circuit efficiently dissipates heat from the motor while the enclosed design prevents dust contamination, ensuring reliable motor operation in the harsh grinding environment.
3Manufacturing precision
If multiple grinding machines are used for different tasks, then the manufacturing precision for each specific task is improved, but the device complexity of the overall system increases
Solution Approach 1:
The grinding machine is designed as a multi-functional device with a pivotable grinding unit that can process both sides of the rail profile. The grinding unit can be positioned at various angles to machine different surfaces including the rail head, web, and foot, allowing one machine to replace multiple specialized machines while maintaining task-specific machining precision.
Solution Approach 2:
The grinding unit is mounted on a motor frame that is adjustable relative to the support frame, adding a dimensional aspect of adjustability. This allows the grinding tool to reach various points on the rail profile by adjusting the position and angle of the motor frame, enabling one machine to perform tasks that would traditionally require multiple fixed machines.
4Strength
If the grinding unit is made heavily robust for durability, then the strength is improved, but the weight of the moving object increases
Solution Approach 1:
The grinding machine is divided into modular components including a support frame, motor frame, and grinding unit. This segmentation allows each component to be optimized for its specific function with appropriate strength-to-weight ratio, rather than making the entire machine heavily robust. The modular design also facilitates easier transport and maintenance.
Solution Approach 2:
The grinding unit is pivotably mounted in the motor frame about a longitudinal axis, creating a dynamic structure that can adapt its configuration during operation. This dynamic mounting allows the grinding unit to be positioned optimally for different machining tasks while maintaining structural integrity, reducing the need for excessive material throughout the entire machine structure.
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 machine achieves high accuracy and efficiency in processing rail profiles by allowing 180° pivoting of the grinding unit, effective dust protection, and energy autonomy, reducing the need for multiple machines and enhancing maintenance and transportability.
Implementation Method 1
the grinding machine includes a heat exchanger and a pump, and that the electric motor is equipped with liquid cooling
Implementation Method 2
a support frame that can be rolled on the rails via guide rollers
Data Source
Figure 1
Figure 2~3
Figure 4~7
AI summary
A grinding machine (1) which can be displaced manually on a track (3) in the track longitudinal direction (13) for grinding rails (2) of the track (3), having a supporting frame (5) which can roll on the rails (3) via guide rollers (4) and on which there is arranged an energy module (6) and a work module (7), wherein the work module (7) comprises a pivotable grinding unit (10). There is provision here that the grinding unit (10) comprises an electric motor (28) and a grinding tool (29) driven thereby, that the grinding unit (10) is mounted in a motor frame (9) so as to be pivotable about a longitudinal axis, and that the motor frame (9) is arranged adjustably with respect to the supporting frame (5).