Rail Mounting Assembly Segmentation for Reusable Anchor Bolts
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Solution Overview
Problem
Existing rail mounting assemblies to concrete foundations are inefficient as they require full demolition of the foundation when rails need replacement, due to damaged anchor bolts and long concrete hardening times, leading to disruptions in tram services.
Innovation Solution
A mounting assembly using temporary plugs and screws with shape-retaining auxiliary pieces that allow rail securing during initial concrete hardening, enabling easy replacement and reuse of components, and allowing trams to operate before full hardening is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If anchor bolts are embedded in the concrete foundation during pouring, then the rail can be secured to the foundation, but the anchor bolts cannot be removed for reuse and the concrete foundation must be fully demolished when rails need replacement
Solution Approach 1:
The mounting assembly is divided into separate components: a reusable mounting part with mounting holes and replaceable anchor bolts. The mounting part remains in the concrete foundation while the anchor bolts can be removed and replaced. This segmentation allows the rail to be secured firmly (improving ease of manufacture) while enabling selective replacement of only the anchor bolts rather than the entire foundation (improving ease of repair).
Solution Approach 2:
The invention enables recovery and reuse of the mounting part and anchor bolts. When rails need replacement, the anchor bolts are removed from the old rail and can be reused with new rails after minimal processing. The mounting part embedded in the concrete foundation is also recovered and reused. This discarding and recovering principle directly addresses the worsening feature by making rail replacement economical and practical without full foundation demolition.
2Strength
If conventional anchor bolts are used that are embedded in the concrete, then the rail is securely mounted, but the concrete foundation must be fully demolished when rails need replacement due to damaged bolts and threads
Solution Approach 1:
The mounting assembly separates the permanent embedded mounting part from the replaceable anchor bolts. The mounting part with mounting holes is embedded in the concrete foundation and provides structural strength. The anchor bolts are separate components that can be independently replaced. This segmentation maintains mounting strength while enabling quick replacement of only the worn bolts, avoiding full foundation demolition and reducing service disruption time.
Solution Approach 2:
The anchor bolts are designed to be removable and recoverable. When they become damaged or worn, they are unscrewed from the mounting part and can be reused after minimal maintenance or replaced with new bolts. The mounting part embedded in the concrete is also recovered and reused. This approach maintains strong mounting while dramatically reducing the time and disruption associated with rail replacement compared to full foundation demolition.
3Duration of action of stationary object
If the concrete foundation is used for over 60 years, then the foundation has long lifespan, but the rails have much shorter lifespan of 6-30 years requiring replacement
Solution Approach 1:
The mounting assembly is segmented into a permanent mounting part embedded in the concrete foundation and replaceable anchor bolts. This allows the foundation to maintain its 60+ year lifespan while the rails and their mounting components can be replaced every 6-30 years. The segmentation enables selective replacement of rail-mounted components without affecting the permanent foundation structure.
Solution Approach 2:
The mounting part and anchor bolts are designed for recovery and reuse across multiple rail replacement cycles. When rails are replaced every 6-30 years, the mounting part remains embedded in the foundation and the anchor bolts are removed, cleaned, and reused with new rails. This discarding and recovering principle allows the foundation to serve for decades while accommodating multiple generations of rails, resolving the contradiction between foundation longevity and rail replacement frequency.
4Ease of repair
If the concrete foundation is fully demolished for rail replacement, then new rails can be installed, but tram services are disrupted for a long time due to concrete hardening requirements
Solution Approach 1:
The mounting assembly segments the mounting function into a permanent embedded mounting part and replaceable anchor bolts. This allows rail replacement to involve only unscrewing and replacing the anchor bolts, a quick process that does not require demolishing the concrete foundation. The segmented design makes rail replacement feasible and rapid, directly addressing both ease of repair and minimizing service disruption time.
Solution Approach 2:
The anchor bolts and mounting part are designed to be recovered and reused rather than discarded. When rails need replacement, the anchor bolts are unscrewed from the mounting part, and both components are preserved for reuse with new rails. This eliminates the need for full foundation demolition and allows rail replacement to be completed quickly, significantly reducing tram service disruption time while maintaining ease of repair.
Data Source
AI summary
Mounting assembly for mounting a rail to a concrete foundation of a railbed, wherein the mounting assembly comprises a mounting part on which the rail sits, and at least two plugs to be accommodated in the concrete foundation, wherein the plugs are provided with an internal channel for accommodating a screw which is screwed into the plug from above through a mounting opening in the mounting part, wherein the plug has a first coupling member and the mounting part has a second coupling member for cooperation with the first coupling member, wherein the cooperating coupling members constitute a form lock that blocks rotation of the plug relative to the mounting part about the centre line of the internal channel.