Switch Blade Reprofiling With Counterholder Rail Protection
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Solution Overview
Problem
Existing methods for reprofiling rail tracks, particularly at switches, are inefficient and often result in damage to the stock rail, leading to longer maintenance times and increased costs due to the need for manual labor and inability to perform reprofiling on continuous track sections.
Innovation Solution
A method involving a processing vehicle with an adjustable first processing unit and counterholder to reprofile the tongue of a switch by creating a gap between the tongue and the stock rail, allowing for transverse stabilization and preventing direct contact with the stock rail during machining, thereby avoiding damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reprofiling is performed on switch tongues using conventional methods, then the running surface can be restored, but the stock rail is damaged and maintenance time increases
Solution Approach 1:
A counterholder is introduced as an intermediary element between the machining tool and the tongue to be machined. The counterholder provides a stable reference surface for the machining operation, allowing precise reprofiling of the tongue without the machining tool contacting or damaging the stock rail. The counterholder acts as a mediator that enables the machining process while protecting the adjacent stock rail from harmful effects.
Solution Approach 2:
The machining system is segmented into separate functional components: the processing vehicle, the machining tool, and the counterholder. This segmentation allows the counterholder to be positioned independently to provide support only where needed (against the tongue to be machined), while leaving the stock rail untouched. The separation of functions enables precise control over which rail elements are contacted during machining.
2Ease of manufacture
If manual processing tools are used for switch areas, then reprofiling can be performed, but productivity decreases and closure time increases
Solution Approach 1:
The processing vehicle is designed with universal functionality to handle both continuous track sections and switch areas. By integrating the counterholder mechanism, the same vehicle can perform automated reprofiling on regular tracks and on switch tongues, eliminating the need for separate manual operations. This multi-functionality maintains ease of manufacture while significantly improving productivity by reducing closure times.
Solution Approach 2:
The counterholder is designed to be self-positioning and self-supporting during the machining operation. It automatically provides the necessary reference surface and support for the tongue to be machined without requiring additional manual intervention or complex setup procedures. This self-service capability enables the processing vehicle to operate autonomously in switch areas, greatly improving productivity.
3Stability of the object's composition
If the tongue is positioned against the stock rail for reprofiling, then stability is provided, but the stock rail cannot be processed without damage
Solution Approach 1:
The counterholder serves as an intermediary that provides stability to the tongue during machining without requiring contact with the stock rail. By positioning the counterholder between the machining tool and the tongue, and having the tongue abut against the counterholder rather than the stock rail, the system achieves the necessary stability while preventing damage to the stock rail. The counterholder mediates the interaction between the machining process and the tongue, isolating the stock rail from harmful effects.
Data Source
Figure 1
Figure 2
AI summary
A method for reprofiling a switch blade (11, 12) in points (2) laid in a railway track (1) using a first machining unit (35) which is held on a machining vehicle (34) and has a machining tool (33). For the profile machining, that switch blade (11, 12) which is to be reprofiled is arranged at a distance in the transverse direction from a stock rail (9, 10) interacting therewith, with a gap (39) being formed. A counter holder (40) which is held on the machining vehicle (34) is moved into the gap (39), wherein, during the profile machining, the machining vehicle (34) is guided along the switch blade (11, 12) and the latter is pressed by the machining tool (33) against the counter holder (40) and is supported thereon.