Rail Welding Unit Layout for Guide-Free Force Transmission
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Solution Overview
Problem
Existing welding units for rails face high demands on unit guides and clamping devices due to the need to apply high tensile forces during the welding process, leading to stress on the bearings and inefficient force transmission.
Innovation Solution
The displacement cylinders are connected such that the cylinder body is attached to one unit part and the piston rod to the other, decoupling the unit guides from power transmission, allowing them to guide without bearing clamping forces, and arranging clamping jaws and cylinders in a common plane to minimize stress and bending moments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the unit guides are used to support both guiding and clamping functions, then the structure is simplified, but the unit guides are subjected to high tensile and compressive forces leading to stress on bearings
Solution Approach 1:
The welding unit is divided into two independent functional systems: the unit guides (guiding system) and the displacement cylinders with clamping devices (power transmission system). The unit guides exclusively provide guiding function while the displacement cylinders handle both clamping and power transmission, separating the previously combined functions to eliminate stress on the guides.
Solution Approach 2:
The displacement cylinders serve as an intermediary component that transfers the clamping force from the clamping devices to the rail ends. By connecting the cylinder body to one unit part and the piston rod to the other, they efficiently transmit longitudinal forces without involving the unit guides in the force transmission path.
2Ease of operation
If the clamping cylinders are arranged above the unit guides in a tong-shaped design, then the clamping function is achieved, but the bearings of the unit parts on the guide column are stressed
Solution Approach 1:
Instead of arranging the clamping cylinders above the unit guides as in traditional tong-shaped designs, the cylinders are positioned such that their longitudinal axes align with the neutral axis of the rails in a common plane. This inversion of the traditional arrangement eliminates bending moments and stress on the bearings while maintaining effective clamping.
3Device complexity
If spaced force axes are used for displacement and clamping cylinders, then structural arrangement is simplified, but additional bending stresses occur in the unit parts
Solution Approach 1:
The displacement cylinders and clamping cylinders are arranged asymmetrically such that their longitudinal axes lie in a common plane aligned with the neutral axis of the rails. This specific asymmetric arrangement eliminates bending stresses by ensuring all forces act through the neutral axis, preventing rotational moments while maintaining structural efficiency.
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 design reduces stress on the unit guides and clamping devices, enabling efficient transmission of longitudinal forces and achieving high clamping forces without introducing tensile or compressive forces into the guides, resulting in a stable and modular welding unit.
Implementation Method 1
The two unit parts are connected by means of the displacement cylinders, in that a cylinder body of the respective displacement cylinder is connected to one unit part and a piston rod of the respective displacement cylinder is connected to the other unit part
Implementation Method 2
each unit part comprises clamping cylinders coupled with clamping jaws below the unit guides for clamping the rails
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a welding unit (1) for welding rails (14) of a track, having a first unit part (2), which can be displaced on unit guides (4) in a rail longitudinal direction with respect to a second unit part (5) by means of displacement cylinders (3), wherein each unit part (2, 5) comprises clamping cylinders (11), coupled by clamping jaws (12) underneath the unit guides (4), for clamping the rails (14). The two unit parts (2, 5) are connected by means of the displacement cylinders (3), in that a cylinder body (15) of the corresponding displacement cylinder (3) is connected to the one unit part (2 or 5) and a piston rod (16) of the corresponding displacement cylinder (3) is connected to the other unit part (5 or 2). There is therefore no need to support the displacement cylinders (3) against a front-side crossmember.