Railway Intermediate Layer Clearing Device Automation
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Solution Overview
Problem
The existing manual method for replacing intermediate layers between rails and sleepers is slow and labor-intensive, with work rates limited to about 30 meters of track per hour, necessitating a more efficient and automated process.
Innovation Solution
A clearing device with a broaching head and elongated guide body is used in conjunction with a vehicle arrangement that includes screwing machines and a lifting device to automate the removal and insertion of intermediate layers, featuring broaching fingers, feed tongs, and rollers for navigating uneven track surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual method is used to replace intermediate layers, then labor intensity is reduced, but productivity is limited to 30 meters per hour
Solution Approach 1:
The clearing device is designed to be self-propelling, moving automatically along the rail under its own weight and the pulling force of the broaching fingers, eliminating the need for external propulsion equipment and operators to manually push or pull the device throughout the track section.
Solution Approach 2:
The broaching fingers are designed to extract and remove the intermediate layers from between the rail and sleepers by engaging them with the broaching hooks and pulling them out through the clearing head, separating the removal function from the overall replacement process.
2Productivity
If automated clearing device is introduced, then productivity increases, but device complexity increases
Solution Approach 1:
The clearing device is divided into distinct functional modules: the clearing head with broaching fingers for removing intermediate layers, the guide body for maintaining alignment and stability, and the feed drive mechanism for propulsion. This segmentation allows each component to perform its specific function efficiently while simplifying the overall design and maintenance.
Solution Approach 2:
The clearing device is designed to handle multiple tasks within a single integrated structure: it removes intermediate layers, guides itself along the rail, and can accommodate variations in track conditions through its resilient broaching fingers and adjustable components, reducing the need for multiple specialized devices.
3Productivity
If broaching fingers with hooks are used, then intermediate layers are removed efficiently, but risk of damage to rail foot increases
Solution Approach 1:
The broaching fingers are designed with resilient elements and controlled engagement mechanisms that allow them to flex and absorb shocks before making contact with the rail foot, preventing sudden impacts or excessive forces that could cause damage while maintaining effective removal of intermediate layers.
Solution Approach 2:
The broaching hooks are specifically designed with localized contact points and controlled engagement geometry that concentrate the removal force on the intermediate layers while distributing any potential stress away from the rail foot, ensuring selective action on the target material without harming the rail structure.
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
AI summary
The invention relates to a method for removing or replacing intermediate layers between rails (5) and railway sleepers (1) or railway sleeper plates (2). After locking the rail screws, the rail is lifted from the railway sleepers, and a lifting device is displaced between the railway sleepers (1) or railway sleeper plates (2) and the lifted rail (5). The invention also relates to a clearing device for clearing rail intermediate layers, comprising a clearing head (10) which is arranged in the front thereof in the direction of advancement and a subsequent elongated guiding body (11). The clearing device extends over at least three railway sleepers (1), and comprises an additional advancement drive.