Railway Tie Anchor Bolt Embedding via Segmented Formwork Stems
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Solution Overview
Problem
The existing casting process of reinforced concrete railway ties with embedded anchor bolts is labor-intensive and costly, requiring manual mounting of anchor bolts after extraction from the formwork, and faces challenges with inclined anchor bolt positions that can lead to undercuts preventing vertical extraction.
Innovation Solution
The process involves embedding two pairs of anchor bolts coupled to plugs during the extraction of the railway tie from the formwork, using a formwork with conical seats and bushes to align and secure the anchor bolts, allowing vertical extraction even with inclined bolt positions, thereby eliminating the need for manual mounting and preventing undercuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If anchor bolts are manually mounted after extraction from formwork, then labor costs and time consumption increase, but the process allows flexibility in anchor bolt positioning
Solution Approach 1:
The patent applies preliminary action by embedding the anchor bolts into the concrete during the casting process itself, rather than mounting them afterward. The formwork includes vertical stems with plugs that receive the anchor bolts before concrete is poured, so the bolts are already in position when the concrete sets. This eliminates the need for manual mounting after extraction and significantly improves manufacturing efficiency.
2Manufacturing precision
If anchor bolts are positioned at inclined angles to match rail support surfaces, then proper rail fixation is achieved, but undercuts form that prevent vertical extraction from formwork
Solution Approach 1:
The patent segments the anchor bolt system into two functional parts: the inclined anchor bolts embedded in the concrete for proper rail fixation, and the vertical extraction stems with plugs that remain perpendicular to the extraction direction. The stems are separate from the bolts themselves, allowing the bolts to be inclined while the stems maintain vertical orientation for easy extraction. This segmentation resolves the contradiction between achieving proper bolt inclination and enabling vertical extraction.
Solution Approach 2:
The vertical stems with plugs act as intermediaries between the formwork and the inclined anchor bolts. The stems are embedded vertically in the formwork and have plugs that receive the anchor bolts. During extraction, the vertical stems allow the formwork to be removed vertically without creating undercuts, while the anchor bolts remain inclined to match the rail support surfaces. The intermediary stems decouple the extraction direction from the bolt inclination requirement.
3Ease of operation
If formwork extraction is performed vertically, then extraction simplicity is maintained, but inclined anchor bolts create undercuts that block extraction
Solution Approach 1:
The patent segments the anchor bolt system into two functional parts: the inclined anchor bolts embedded in the concrete for proper rail fixation, and the vertical extraction stems with plugs that remain perpendicular to the extraction direction. The stems are separate from the bolts themselves, allowing the bolts to be inclined while the stems maintain vertical orientation for easy extraction. This segmentation resolves the contradiction between achieving proper bolt inclination and enabling vertical extraction.
4Ease of manufacture
If manual mounting of anchor bolts is used, then labor intensity increases, but anchor bolts can be precisely positioned after concrete setting
Solution Approach 1:
The patent applies preliminary action by embedding the anchor bolts into the concrete during the casting process itself, rather than mounting them afterward. The formwork includes vertical stems with plugs that receive the anchor bolts before concrete is poured, so the bolts are already in position when the concrete sets. This eliminates the need for manual mounting after extraction and significantly improves manufacturing efficiency.
Data Source
Figure 1A~1C
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Figure 5
AI summary
Casting process of reinforced concrete railway ties, wherein one or two pairs of anchor bolts are embedded in the railway ties while the concrete sets in the formwork, each one of said anchor bolt being suitable for being coupled with a fixing plate for the rails that are supported by the railway tie.