Rail Welding Collar for Broken Rail Repair
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Solution Overview
Problem
The existing methods for repairing broken railway rails are complex and expensive, requiring provisional securing of the break, removal of temporary fixtures, and separate steps for welding, which complicates the process.
Innovation Solution
A welding collar that bridges the gap in the rail, providing a cavity for unhindered electrode movement during butt welding and acting as a weld pool backup, allowing for simultaneous fixation and repair of the rail in a single operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional strap is used for provisional securing of a broken rail, then the break can be temporarily fixed, but the repair process becomes complex and expensive requiring removal of the strap and separate welding operations
Solution Approach 1:
The welding collar combines the provisional fixation function and the weld pool backup function into a single integrated component. The collar serves both as a temporary securing element that can be quickly installed on broken rails and as a protective structure for the subsequent welding operation, eliminating the need for separate strap installation and removal steps
Solution Approach 2:
The welding collar performs multiple functions simultaneously: it provides provisional mechanical support to the broken rail ends, centers the rail sections alignment, and acts as a backup for the weld pool during arc welding. This multi-functionality replaces the need for multiple separate tools and procedures in the traditional repair method
2Reliability
If the welding sleeve is placed directly against the rail in the gap area, then it provides good weld pool backup, but it prevents the electrode from oscillating during butt welding
Solution Approach 1:
The welding collar has varying proximity to the rail at different locations: in the gap area it is spaced away from the rail to allow electrode oscillation, while in the areas adjacent to the gap it rests closely against the rail to provide effective weld pool backup. This local variation in spacing optimizes both welding accessibility and weld protection
3Ease of manufacture
If multiple separate operations are used for rail repair (provisional securing, then welding), then each step can be optimized independently, but the overall repair time and cost increase
Solution Approach 1:
The welding collar is pre-installed on the broken rail before the welding operation begins. This preliminary action of installing the collar serves dual purposes: it provides immediate provisional fixation to secure the broken ends, and it prepares the weld pool backup structure in advance, so that when welding starts, the protective structure is already in place and no additional setup time is needed
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
Simplifies the repair process by enabling one-step fixation and welding of broken rails, reducing costs and operational complexity while ensuring proper alignment and stabilization of rail parts.
Implementation Method 1
The actual repair, i.e. butt welding, usually takes place later... The repair welding (arc welding) is then carried out by welding the rail foot, mounting copper jaws to protect the weld pool and welding the web and rail head
Implementation Method 2
mounting copper jaws to protect the weld pool... the welding sleeve... serving as a weld pool backup for the subsequent repair welding
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Means and method for butt-welding of a gap in a railway rail, in particular for butt-welding a rail rupture, wherein a welding sleeve (2) is used which flanks the rail (3) in the longitudinal direction on its two longitudinal sides (10, 11) in a rail region (9) comprising the gap region (7), bridges the gap (8) and is fixedly connected to the rail (3) on both sides of the gap (8) with respect to the longitudinal direction of the rail (3), wherein the welding sleeve (2) encompasses a first fishplate (12) which flanks the rail (3) on its first longitudinal side (10) in the longitudinal direction and a second fishplate (13) which flanks the rail (3) on its second longitudinal side (11) in the longitudinal direction, and wherein the first fishplate (12) and the second fishplate (13) are each spaced apart in the gap region (7) from the rail web (5) and the part of the rail head (4), with the result that a cavity or channel (15) which is delimited by the fishplates (12, 13) and surrounds the gap (8) is formed in the gap region (7) on both longitudinal sides (10, 11) of the rail (3) at least in the region of the rail web (5) and of the part of the rail head (4).