Rail Web Tubular Element Track Section Connection
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Solution Overview
Problem
Existing track section connections, particularly in frog points and wing rails, face issues with loose screw connections and residual stress from welding, leading to structural instability and material changes.
Innovation Solution
A track section design where tubular elements are connected to the rail web via a press fit, with the spacer's end face set back from the rail web's outer surface, allowing for indirect welding that maintains the structural integrity of the components and avoids direct welding stress, using materials like steels from group 1.2 and processes like inert gas welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If high-strength bolts are used to connect the spacer piece to the track components, then assembly effort is minimized and the connection is cost-effective, but the connection can loosen under high loads
Solution Approach 1:
The patent replaces the mechanical bolted connection system with a material-bonded connection system (welding). The spacer piece is connected to the rail web and frog point through material bonding instead of high-strength bolts, eliminating the loosening issue while maintaining assembly efficiency. The welding process creates a permanent, load-resistant connection that substitutes the mechanical fastening system.
2Strength
If the spacer piece is welded directly to the rail web, then a secure connection is achieved, but stress concentrations and material changes occur in the rail
Solution Approach 1:
The patent introduces the tubular element as an intermediary component between the spacer piece and the rail web. The material-bonded connection is performed between the spacer piece and the tubular element, not directly to the rail web. This intermediary arrangement allows the welding heat and stress to be contained within the tubular element, preventing stress concentrations and material changes in the rail web while maintaining connection strength.
Solution Approach 2:
The connection system is segmented into distinct components: the rail web, the tubular element, and the spacer piece. The material-bonded connection is localized to the interface between the spacer piece and tubular element, separating the welding zone from the rail structure. This segmentation prevents harmful thermal and mechanical effects from affecting the rail material.
3Device complexity
If direct welding between spacer and rail is performed, then assembly is simplified, but residual stress and structural changes are introduced
Solution Approach 1:
The tubular element serves as a mediator that isolates the welding process from the rail structure. The spacer piece is material-bonded to the tubular element, creating a secure connection without directly welding to the rail. This maintains structural stability of the rail while achieving assembly simplification.
4Ease of manufacture
If conventional screw connections are used to prevent relative movement, then assembly is simple, but the connections can loosen under load
Solution Approach 1:
The patent replaces the mechanical screw connection system with a material-bonded connection system. Instead of using screws that can loosen, the spacer piece and tubular element are permanently joined through welding, creating a load-resistant, maintenance-free connection that eliminates the loosening problem while keeping assembly simple.
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
This solution provides a secure, high-load-bearing connection with minimal assembly work, preventing structural changes and residual stress, ensuring a permanent distance between track components while allowing any rail quality to be used.
Implementation Method 1
the tubular element is connected to the rail web by a press fit
Implementation Method 2
the spacer piece is joined to at least one of the track components having a rail web in its web area by means of a material bond
Data Source
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AI summary
The invention relates to a track section comprising track components (1, 6) connected to one another via a spacer (4, 13), wherein at least one first track component has a rail web (23, 28). To ensure that a secure connection capable of withstanding high loads is achieved with a simple design, thereby guaranteeing a permanent gap between the track components, it is proposed that a tubular element (2, 5) extends from the rail web (23, 28) of the first track component (1, 6) and is materially bonded to the spacer (4, 13).