Tiltable Abrasive Module for Rail Grinding
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Solution Overview
Problem
Existing rail grinding technologies face challenges in efficiently removing surface irregularities and millscale while minimizing residual debris, dust, and water usage, and lack flexibility in adapting to complex rail shapes.
Innovation Solution
A vehicle-mounted abrasive module with tiltable and individually pressable abrasive blocks driven by an eccentric mechanism, combined with a debris suction system, enables high metal removal and low residual roughness without leaving debris on the track.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing grinding machines use multiple abrasive blocks in a fixed series, then the structure is simple, but the flexibility in treating complex rail shapes is limited
Solution Approach 1:
The abrasive tool is divided into multiple independent abrasive blocks (first, second, third abrasive blocks) that can be independently positioned and angled. Each block can be individually adjusted to contact different portions of the rail head, allowing treatment of complex rail shapes including curves and transitions while maintaining a relatively simple overall structure.
Solution Approach 2:
The abrasive blocks are mounted on pivotable tool supports that allow angular adjustment. The tool supports can be pivoted about vertical axes, and the abrasive blocks themselves can be angled relative to the rail head, providing dynamic adaptability to various rail geometries without requiring a completely complex reconfigurable structure.
2Adaptability or versatility
If existing machines use a fixed series of abrasive blocks pressed onto the rail, then the device complexity is reduced, but the ability to individually press blocks onto the rail is lost
Solution Approach 1:
Each abrasive block is equipped with its own independent pressing mechanism (first, second, and third pressing mechanisms). This allows each block to be pressed onto the rail head independently, enabling selective application of pressure to different blocks based on the specific treatment requirements of various rail sections.
Solution Approach 2:
The pressing mechanisms are designed to be independently controllable, allowing dynamic adjustment of the pressing force applied to each abrasive block. This enables the system to adapt the pressing force distribution according to the rail geometry and treatment needs without requiring a completely complex centralized control system.
3Productivity
If existing grinding machines use rotational to linear movement mechanism with short stroke, then the device complexity is minimized, but the metal removal efficiency is reduced
Solution Approach 1:
The abrasive blocks perform oscillating movements with relatively large strokes along the rail head. The tool supports oscillate back and forth, causing the abrasive blocks to traverse larger portions of the rail head surface during each oscillation cycle, thereby increasing metal removal efficiency while maintaining a relatively simple oscillating mechanism based on conventional gearboxes and excenter mechanisms.
4Object-affected harmful factors
If existing technology uses significant amounts of water for cooling, then the cooling effect is sufficient, but the water consumption and environmental impact increase
Solution Approach 1:
The patent reduces the amount of water used for cooling the abrasive blocks during rail head treatment. By optimizing the cooling system parameters (reducing water flow rate and coverage area), the system achieves adequate cooling effects with significantly lower water consumption, thereby reducing environmental impact and water waste while maintaining effective temperature control of the abrasive blocks.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves efficient metal removal with minimal residual roughness and debris, adapts to complex rail shapes, and reduces water consumption, enhancing maintenance efficiency and environmental impact.
Implementation Method 1
a metal abrasive module, an eccentric drive (3) performing an eccentric movement, at least two abrasive blocks (4) connected with the eccentric drive (3)
Implementation Method 2
abrasive blocks (4) which are in contact with the rail... allowing for removing rail surface irregularities such as corrugations, near surface defects, and millscale
Data Source
Figure 1~2
Figure 3(a)~4(c)
Figure 5~6
AI summary
Vehicle for machining a rail (1) by grinding and/or planing, comprising a metal abrasive module (2), an eccentric drive (3) performing an eccentric movement, at least two abrasive blocks (4) connected with the eccentric drive, and a force exerting drive (5) pressing at least one abrasive block onto the rail, wherein the metal abrasive module and/or at least one of the abrasive blocks is individually tiltable around an axis parallel to the rail, and wherein at least one of the abrasive blocks is individually pressable onto the rail. This allows a more effective and improved metal removal and rail shaping capabilities.