Railway Track Substructure Repair via On-Site Material Recovery

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Solution Overview

Problem

Existing methods for repairing track systems are costly and environmentally impactful due to the transportation and disposal of removed substructure material, which is often contaminated, and the need for new material, leading to increased land use and labor.

Innovation Solution

The method involves the separate removal and reuse of material from the mixing zone as part of the new substructure, reducing the need for transporting and disposing of old material and using new material, with the option to reprocess and reinstall ballast, and adding additives to improve the properties of the reinstalled material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the removed substructure material is transported away and disposed of, then the new substructure can be made with new material, but the transport and disposal costs increase and land consumption increases

Engineering Contradiction:

Improvequality of new substructureVSAvoidmaterial consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent recovers and reuses the removed substructure material (mixing zone material) instead of disposing of it. The material is separated into usable portions that are reused in the new substructure, reducing the need for new material and associated transport/disposal costs while maintaining structural quality.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The patent changes the parameter of material utilization by transforming the removed mixing zone material from waste into a useful resource. The material is processed and reused with appropriate quality control, changing its status from discarded material to constructive element.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the removed substructure material is transported away and disposed of, then the new substructure can be made with new material, but the transport and disposal costs increase

Engineering Contradiction:

Improvequality of new substructureVSAvoidtransport and disposal energy

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

By recovering and reusing the removed substructure material on-site, the patent eliminates the energy-consuming processes of transportation and disposal. The material is processed and reused locally, significantly reducing the energy required compared to transporting and landfilling the entire removed material.

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If new material is used for the new substructure, then the substructure quality can be ensured, but the land consumption increases

Engineering Contradiction:

Improvequality of new substructureVSAvoidland consumption

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent recovers and reuses the removed substructure material to construct the new substructure, eliminating the need to import entirely new material. This reduces land consumption for material storage, processing, and disposal while maintaining the quality requirements of the new substructure through controlled material reuse.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentEP2166152B1Method and device for improving or repairing track systems

Publication Date: 2016.06.01 KNAPE GRUPPE HLDG

Figure 1

AI summary

The method involves removing ballast of ballast subsstructure (4), and removing material of a substructure (5) up to a desired depth. New substructures (8,9,10) are installed for producing new ballast (11). The removing material is separated from a mixing zone (6) in a transitional area between ballast substructure and the substructure. An independent claim is included for a device for improving or repairing railway tracks.