Prefabricated Wire Mesh Ballast Assembly with Integrated Injection Pipes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional gravel-ballasted tracks face issues with deformation due to train loads and water accumulation, leading to settlement and maintenance challenges, particularly with the complex installation of separate injection pipes for stabilizing materials.
Innovation Solution
A prefabricated wire mesh assembly with an internal partition wall and pre-installed injection pipes is used, allowing for efficient injection of filling material without additional pipe installations, and featuring a drainage pipe to prevent water infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate injection pipes are installed through vertical boreholes for ballast reinforcement, then the gravel ballast can be reinforced without separately replacing the existing gravel ballast, but the constructability is limited and maintenance becomes difficult
Solution Approach 1:
The patent combines multiple functions into a single integrated structure: the wire mesh assembly serves as both the ballast reinforcement framework and the injection pipe support system. The injection pipes are pre-installed on the wire mesh assembly, eliminating the need for separate pipe installation through boreholes. This merging of functions resolves the contradiction by maintaining reinforcement effectiveness while dramatically improving constructability and maintenance ease.
Solution Approach 2:
The injection pipes are pre-installed on the wire mesh assembly during manufacturing, before the actual ballast reinforcement operation. This preliminary action eliminates the need for complex on-site pipe installation through vertical boreholes, thereby improving constructability while maintaining the reinforcement function.
2Reliability
If injection pipes are individually installed through vertical boreholes, then ballast stabilizing material can be injected into gaps within the gravel ballast, but additional installation work is required which increases construction complexity
Solution Approach 1:
The patent merges the injection pipe system with the wire mesh assembly into a single integrated structure. The injection pipes are pre-installed on the wire mesh assembly, which eliminates the need for separate pipe installation operations. This integration reduces construction complexity while maintaining the ballast stabilization function.
Solution Approach 2:
The injection pipes are pre-installed on the wire mesh assembly during manufacturing, before the actual ballast reinforcement operation. This preliminary action eliminates the need for complex on-site pipe installation through vertical boreholes, thereby reducing construction complexity while maintaining stabilization effectiveness.
3Strength
If rebar meshes are stacked in an inclined manner to form ballast shoulder, then the ballast shoulder can be reinforced, but separate fixing brackets and angle brackets are required which increases device complexity
Solution Approach 1:
The patent combines the ballast shoulder reinforcement function with the wire mesh assembly itself. The wire mesh assembly is configured to form the ballast shoulder structure directly, eliminating the need for separate fixing brackets and angle brackets. This integration maintains reinforcement strength while reducing device complexity.
4Power
If multiple injection ports are formed separately in the rebar mesh, then injection material can be injected at high pressure, but the manufacturing cost inevitably increases
Solution Approach 1:
The patent combines multiple injection ports into a single integrated injection pipe system that is pre-installed on the wire mesh assembly. This merging reduces the number of separate components needed while maintaining the capability for high-pressure injection material delivery, thereby reducing manufacturing costs.
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
This solution enhances injection efficiency, reduces construction complexity, and prevents water-induced subsidence, allowing for effective stabilization and maintenance of gravel-ballasted tracks without the need for separate ballast shoulders.
Implementation Method 1
a ballast stabilizing material 9 is injected through head parts 11 of the injection pipes 15. The ballast stabilizing material 9 is injected into gaps within the gravel ballast 3 and solidified.
Implementation Method 2
the gravel particles 2 are bound together through the solidification of the injection material
Implementation Method 3
a drainage pipe, which is pre-installed at the bottom of the wire mesh assembly, to prevent rainwater and the like from infiltrating into the gravel ballast and from being introduced into the roadbed
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Disclosed are a prefabricated wire mesh assembly for a ballast and a method of constructing a gravel-ballasted track using the same. For example, when a gravel ballast (A1) is used by filling a box-shaped rebar mesh with crushed stones (including gravel) and injecting a filling material, the prefabricated wire mesh assembly increases injection efficiency by further installing an internal partition wall to effectively support loads without forming a separate ballast shoulder (A2) and injecting a filling material through injection pipes (120) installed on an internal partition wall (130), and prevents water accumulation on a roadbed by a drainage pipe. The prefabricated wire mesh assembly for a ballast is assembled by installing the injection pipe (120) along with the lower mesh (110) and the internal partition wall (130), thereby allowing the filling material to be injected without installation of a plurality of separate injection pipes (120).