Separable Check Rail for Double Frog Track Crossing Maintenance
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Solution Overview
Problem
The existing double frog designs require significant effort and cost for replacing the check rail due to its integration with the monoblock-cast frog, necessitating the exchange of the entire structure, which leads to service interruptions and high replacement costs.
Innovation Solution
The check rail region with the guide surface is designed to be separably fastened on a check rail mounting within the material block, allowing for the replacement of only the worn-out component, reducing the number of components and installation effort, and enabling the use of wear-resistant materials or coatings, with screw joints for easy exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the check rail is integrated with the monoblock-cast frog, then the durability and strength are improved, but the replacement effort and service interruption increase significantly
Solution Approach 1:
The check rail is divided into a wear-prone region and a non-wear region. The wear-prone region can be separated and replaced independently from the non-wear region, allowing partial replacement without exchanging the entire check rail assembly.
Solution Approach 2:
The wear-prone region of the check rail is extracted as a separate replaceable component. This extracted region can be removed and replaced without affecting the remaining integrated portion, reducing replacement effort and service interruption.
2Ease of repair
If the check rail is made as a separate component, then the replacement effort is reduced, but the number of components and installation complexity increase
Solution Approach 1:
The check rail is segmented into a wear-prone region and a non-wear region. The non-wear region remains integrated with the monoblock-cast frog, while the wear-prone region is separated as a replaceable component, achieving a balance between simplicity and maintainability.
Solution Approach 2:
Only the wear-prone region is extracted as a separate component, while the rest of the check rail remains integrated. This selective extraction reduces replacement effort without significantly increasing the number of components.
3Reliability
If the entire double frog is exchanged to replace the check rail, then the reliability is maintained, but the loss of time and cost increase significantly
Solution Approach 1:
The check rail is segmented into replaceable and non-replaceable portions. Only the wear-prone region needs replacement, allowing the rest of the double frog structure to remain in service, thereby reducing service interruption time.
Solution Approach 2:
The wear-prone region is extracted as a separate replaceable component. This allows targeted replacement of only the worn portion without exchanging the entire double frog, minimizing service interruption and maintaining reliability.
Data Source
AI summary
In a double frog for track crossings with two opposing noses that are realized in a common material block and to which a check rail with at least one guide surface for a wheel is assigned, the check rail region featuring the guide surface is separably fastened on a check rail mounting that is realized in one piece with the material block.