Rail Switch Tongue Device Segmented Base Block Design
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Solution Overview
Problem
Existing switch devices for grooved rail switches are complex and costly to manufacture, with high maintenance costs due to intricate constructions and the need for high-strength materials, and they require additional components like sliding plates and complex welding processes.
Innovation Solution
A switch device design where the lower part of the tongue device is constructed as an integral base block made of high-strength steel, eliminating the need for additional sliding plates and using conventional steel for other components, with a form-fitting and material connection between the stock rail and base block for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the entire switch device is manufactured as a monobloc design from a single steel block, then manufacturing tolerances are reduced and production is simplified, but the cost increases significantly due to the need for high-strength materials throughout the entire structure
Solution Approach 1:
The switch device is divided into two main segments: a base block made of conventional structural steel and an upper part made of high-strength steel. This segmentation allows each part to be optimized independently - the base block uses cost-effective conventional steel while the upper part uses high-strength steel only where necessary for structural integrity and tongue support.
Solution Approach 2:
High-strength steel is applied locally only to the upper part of the switch device where it is structurally necessary for supporting the tongue and withstanding operational loads. The base block uses conventional structural steel, avoiding the high cost of high-strength materials in areas where they are not needed.
2Strength
If additional thin high-strength support plates are applied to the tongue bed to achieve desired strength, then the structural integrity is improved, but the production cost increases and the construction becomes more complex
Solution Approach 1:
The tongue bed and base block are merged into a single integral structure. The base block is designed with an integrated tongue bed cavity that directly supports the tongue, eliminating the need for separate support plates or additional components. This integration simplifies the construction while maintaining the required structural strength.
3Reliability
If individual areas are hardened by build-up welding at wear points, then the durability is improved, but the manufacturing time and complexity increase significantly
Solution Approach 1:
The material parameters of the base block are changed by selecting conventional structural steel with appropriate mechanical properties that provide sufficient durability without requiring post-manufacturing hardening treatments. The material selection and structural design are optimized to achieve the required wear resistance and strength through the base material properties rather than through additional hardening processes.
Data Source
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AI summary
The present invention relates to a tongue device (10d) and a method for manufacturing a tongue device (10d). The tongue device (10d) according to the invention exhibits high durability, while the manufacturing effort and costs are very low. Furthermore, the maintenance costs are very low. The tongue device (10d) according to the invention can be made significantly more compact than conventional tongue devices and can be drained much more effectively.