Rail Induction Welding with 3D Alignment for Gapless Joints

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Solution Overview

Problem

Existing methods for welding railway rails, such as thermic and flash-butt welding, result in weak joints, safety hazards, and poor rail alignment, leading to disruptions in train travel and increased risk of derailment due to gaps between rails.

Innovation Solution

A railway rail induction-welding device that aligns rails in three perpendicular directions using clamping and lifting modules, followed by electromagnetic induction to create a strong, continuous weld without stress, and includes a shear die to remove excess material for a smooth transition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermic welding using Goldschmidt reduction process is used, then welding can be achieved, but the weld is weaker than the parent rail and there are safety hazards from flame, pyrotechnic and waste molten metal

Engineering Contradiction:

Improveweld strengthVSAvoidsafety hazards and fire risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical-based thermic welding process with an induction heating system that uses electromagnetic fields to heat and weld the rails. This substitution eliminates the need for thermite, gas flames, and pyrotechnic materials, thereby removing the associated safety hazards and fire risks while maintaining weld integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the heating method from chemical combustion to electromagnetic induction, fundamentally altering the physical and chemical parameters of the welding process. This parameter change results in a cleaner, safer process that produces stronger welds without the harmful byproducts of thermic welding.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If flash-butt welding is used, then welding can be achieved, but rail alignment is poor and the process requires high power hydraulic stressing

Engineering Contradiction:

Improveweld strengthVSAvoidrail alignment

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The induction welding device incorporates alignment mechanisms that precisely position and align the rail ends before the welding process begins. This preliminary alignment action ensures that the rails are correctly positioned in three-dimensional space, eliminating the alignment problems associated with flash-butt welding and subsequent hydraulic stressing.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If fishplates are used to connect rails, then physical connection is achieved, but a gap remains between the rails disrupting ride smoothness

Engineering Contradiction:

Improveconnection strengthVSAvoidride smoothness

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The invention extracts and eliminates the fishplate connection method entirely, replacing it with direct induction welding of the rail ends. This removal of the intermediate connection component (fishplate) allows for a continuous, gapless rail joint that maintains both structural strength and ride smoothness.

Inventive Principle:

Principle #2Taking out (Extraction)

4Productivity

If conventional welding methods are used, then rails can be joined, but the joints are prone to shearing or stress fractures

Engineering Contradiction:

Improvewelding capabilityVSAvoidjoint resistance to shearing and stress fractures

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent replaces conventional welding methods with induction heating technology, which uses controlled electromagnetic fields to heat and fuse the rail ends. This substitution creates a more uniform and controlled welding process that produces stronger joints resistant to shearing and stress fractures, while maintaining high productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution ensures a strong, smooth, and stable weld without weakening the rails, reducing the risk of derailment and improving train travel by eliminating gaps between rails, while being safer and more environmentally friendly than existing methods.

Implementation Method 1

an induction heating device on the device support and interposed or interposable between the first and second railway-rail clamping elements to inductively weld the opposing railway rails together

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11519135B2Railway rail induction-welding device

Publication Date: 2022.12.06 MIRAGE LTD

AI summary

A railway rail induction-welding device is provided which includes a device support and a railway rail alignment means for aligning opposing railway rails in three mutually perpendicular directions, the railway rail alignment means being supported by the device support. The railway rail alignment means includes first and second railway-rail clamping elements to horizontally and longitudinally align the opposing railway rails when gripped by the first and second railway-rail clamping elements, with at least one of the first and second railway-rail clamping elements being movably supported by the device support, and a vertical lifting means for moving each railway-rail clamping element vertically to align the opposing railway rails. A railway rail clamping and lifting module, a vehicle a railway rail induction-welding device, and a method of inductively welding opposing railway rails together are also provided.