Railway Rail Truncation Apparatus with Autonomous Linkage

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Solution Overview

Problem

Existing rail saws are hazardous due to the proximity of the moving abrasive disc and sparks, cause unhealthy work postures, and require continuous operator intervention, leading to fatigue and muscle strain.

Innovation Solution

A portable cutting apparatus with a rail saw and linkage structure that allows autonomous cyclic movement of the abrasive blade, reducing operator intervention and incorporating a transmission ratio adjuster to compensate for changes in resistive moment and motor speed, along with a sawing position alternator for unassisted rail truncation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a portable rail saw with moving abrasive disc is used for rail truncation, then the rail can be truncated in situ, but the operator is exposed to hazards from sparks, abrasion dust, and proximity to the moving abrasive disc

Engineering Contradiction:

Improvein situ truncation capabilityVSAvoidoperator exposure to sparks, dust, and moving blade

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a linkage structure with guide arms and base portions that acts as an intermediary between the operator and the cutting mechanism. This linkage structure positions the abrasive disc at a safe distance from the operator while maintaining cutting effectiveness, thereby reducing exposure to harmful factors while preserving in situ truncation capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cutting apparatus is divided into separate functional components: a base portion with rail connector, guide arms, and a saw portion with abrasive disc. This segmentation allows the cutting mechanism to be positioned independently away from the operator's position, reducing hazard exposure while maintaining operational versatility

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If the operator continuously holds and manually guides the rail saw during cutting, then control over the cutting process is maintained, but the operator experiences muscle strain and fatigue

Engineering Contradiction:

Improvemanual control of cutting processVSAvoidoperator fatigue and muscle strain

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The linkage structure is designed to lock onto the rail and autonomously guide the cutting process. Once positioned, the structure self-supports the cutting mechanism and maintains proper alignment without requiring continuous operator intervention, thereby eliminating muscle strain while preserving cutting control

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The apparatus is preliminarily positioned and locked to the rail before cutting begins. The linkage structure is pre-configured to provide stable support and guidance, so that once in place, no further manual adjustment or holding is needed during the cutting operation, preventing operator fatigue

Inventive Principle:

Principle #10Preliminary action

3Productivity

If the motor runs at high speed to maintain cutting efficiency, then productivity is improved, but the motor speed varies due to changes in resistive moment during cutting

Engineering Contradiction:

Improvecutting efficiencyVSAvoidmotor speed stability

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

The patent incorporates a transmission ratio adjuster that responds to changes in resistive moment during cutting. When resistance increases, the adjuster automatically modifies the transmission ratio to maintain consistent motor speed, providing feedback control that stabilizes operation while preserving cutting efficiency and productivity

Inventive Principle:

Principle #23Feedback

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 apparatus enables safe, precise, and unassisted rail truncation, reducing operator risk and fatigue, and does not require skilled or physically fit personnel, while maintaining cutting precision and extending equipment lifespan.

Implementation Method 1

a plate holder adapted to carry an abrasive blade and a transmitter that engages the motor output member and the plate holder to set the plate holder in a cyclic movement, so that the abrasive blade itself can truncate the railway rail

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS9017148B2Apparatus for the truncation of railway rails

Publication Date: 2015.04.28 CEMBRE SPA

AI summary

A portable cutting apparatus (1) for the in situ truncation of railway rails (9) comprises a rail saw (2) having a motor (3) with a cyclic movement output member (4), a plate holder (5) adapted to carry an abrasive blade (6) and a movement transmitter (7) engaging the motor output member (4) and the plate holder (5) to set the plate holder (5) in a cyclic movement, a linkage structure (27) with a rail connector (29) and a saw connector (31) and a sawing position alternator (45) to autonomously and alternately move the plate holder (5) to and fro.