Rail Switch Lug Mechanical Lock Design
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Solution Overview
Problem
Current methods for manufacturing lugs for rail switch blades, such as welding or using semi-finished blades, are time-consuming and inefficient due to thermal alterations, complex assembly processes, and quality control requirements, leading to increased costs and production time.
Innovation Solution
Manufacturing lugs as separate parts with two lugs and a central stringer, allowing for horizontal and vertical positioning, with mechanical locks and screw holes for easy assembly and disassembly, enabling use of economically suitable materials and reducing production costs by allowing for lug replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lugs are manufactured as individual parts and welded on the blade, then assembly is possible, but welding time and quality control requirements increase production time and costs
Solution Approach 1:
The lug is divided into a blade component and a separate lug component that can be assembled together. The blade contains a lug recess while the lug component contains a lug body with matching geometry, allowing segmentation of the manufacturing process while maintaining assembly capability through mechanical interlocking rather than welding.
Solution Approach 2:
The welding process is replaced with a mechanical assembly system. The lug component features a lug body with external dimensions that match the lug recess internal dimensions, creating a mechanical fit that eliminates the need for thermal welding processes, thereby reducing production time and quality control requirements.
2Stability of the object's composition
If lugs are manufactured as components of semi-finished blades, then integration is achieved, but processing time and material costs increase
Solution Approach 1:
The integrated blade-lug structure is segmented into separate manufacturable components: a blade with a lug recess and a separate lug component. This allows each component to be manufactured independently using optimized processes, then assembled together, reducing overall machining time while maintaining structural integration.
Solution Approach 2:
The lug recess acts as an intermediary feature that enables connection between the blade and lug components. The recess geometry is designed to match the lug body geometry, creating a precise mechanical interface that ensures proper alignment and integration without requiring extensive machining of the complete assembly.
3Reliability
If thermal pre-heating is applied during welding, then weld quality improves, but thermal alteration of blade material occurs
Solution Approach 1:
The thermal welding process is completely replaced with a mechanical assembly process. The lug component is secured to the blade through the mechanical interlock of the lug body and lug recess, eliminating all thermal effects and associated material alterations while maintaining connection reliability.
Solution Approach 2:
The invention accepts that the lug component may be replaceable rather than permanently bonded, allowing for simpler assembly methods that avoid thermal processes entirely. This approach prioritizes ease of assembly and material preservation over permanent bonding, suitable for applications where replacement is feasible.
Data Source
Figure 1~5
AI summary
The invention concerns the rail switch with blade (1) and lug (2), where the lug (2) is manufactured as a separate part connected to the blade (1) of rail switches with screws (3), wherein the upper part of the lug (2) is equipped with a milled mechanical lock to be placed on the body of the blade (1) and the lug (2) is equipped with a hole to grip the corresponding drive rod. To grip drive rods, in the horizontal version the lugs (2) are equipped with extra holes for plugs, whereas in the vertical version the lugs (2) are equipped with cross grooves.