Rail Welding Head Support for Tension Transfer and Bead Removal
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Solution Overview
Problem
Existing welding heads for rail tracks face challenges in simplifying the welding operation, managing rail tension forces during welding, and minimizing friction with sleepers, which complicates the process and requires larger cranes and obstructs weld bead removal.
Innovation Solution
A welding head with a support device that allows for direct transmission of rail tension forces to the track, reducing friction and enabling smaller crane usage, and includes hydraulically adjustable support rams or sliding rails for efficient positioning and weld bead removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the welding head is lifted during welding operations, then the welding units can move towards one another, but the crane must bear the full weight and tension forces of the raised rails
Solution Approach 1:
A support device is introduced as an intermediary element between the welding head and the track. This support device transfers the tension forces generated by the raised rails directly to the track, relieving the crane from bearing these forces during welding operations while still allowing the welding units to move towards one another
2Ease of operation
If the welding head moves along the track during welding, then the welding units can approach each other, but friction with the sleepers occurs
Solution Approach 1:
The support device acts as a mediator that enables the welding head to move along the track during welding operations without creating harmful friction with the sleepers. It provides a stable reference point that allows movement while preventing direct contact and friction between the welding head and the sleepers
3Stability of the object's composition
If the welding head is fully lowered to the track, then stability is improved, but the shearing knife cannot be moved underneath the rail base for weld bead removal
Solution Approach 1:
The support device provides dynamic positioning capability, allowing the welding head to be positioned at different heights relative to the track. During welding, it can be lowered for stability, and during weld bead removal, it can be raised to allow the shearing knife to move underneath the rail base, thus adapting to different operational requirements
Data Source
AI summary
A welding apparatus for welding rails of a track comprises two welding units which are movable relative to one another and which are each equipped with clamping jaws at a lower end. The clamping jaws are configured for resting on a web of the rail. Each welding unit is connected to a supporting device which can move relative to the welding unit and which is provided for resting on the track during operation.