Track assembly tool

Patent metadata

Field	Value
Publication number	US-2022267963-A1
Application number	US-202017630083-A
Country	US
Kind code	A1
Filing date	Jul 27, 2020
Priority date	Jul 26, 2019
Publication date	Aug 25, 2022
Grant date	—

Abstract

Method of forming track section includes coupling functional components to a framework. At least some of the functional components are arranged in a precise and accurate arrangement in a common plane. Building a rigid, removable, and reusable mold around the framework and functional components. Steel reinforcement (“rebar”), which is bent into a shape corresponding to a track section profile, is provided within the mold. Dispensing a binder material into the mold and curing the binder material; and removing the mold from the cured binder material to reveal a completed track section at required accuracy set by the framework. At least some other functional components are arranged parallel to each other in a first lateral plane normal to the common plane and at least still other functional components are arranged parallel to each other in a second lateral plane normal to the common plane and parallel to the first lateral plane.

First claim

What is claimed is:

1 . A method of forming a track section, comprising:
coupling functional components to a framework, wherein at least some of the functional components are arranged in a precise and accurate arrangement in a common plane; building a rigid, removable, and reusable mold around the framework and functional components, wherein steel reinforcement (“rebar”), which is bent into a shape corresponding to a track section profile, is provided within the mold; dispensing a binder material into the mold and curing the binder material; removing the mold from the cured binder material to reveal a completed track section at the required accuracy set by the framework, wherein at least some other functional components are arranged parallel to each other in a first lateral plane normal to the common plane and at least still other functional components are arranged parallel to each other in a second lateral plane normal to the common plane and parallel to the first lateral plane.

2 . The method according to claim 1 , wherein the at least some functional components in the common plane comprise levitation rails and braking rails.

3 . The method according to claim 1 , wherein the at least some other functional components and the at least still other components comprise guidance rails and propulsion rails.

4 . The method according to claim 1 , wherein the framework includes placeholders arranged to receive and position the functional elements coupled to the framework.

5 . The method according to claim 1 , wherein the functional elements comprise anchors arranged to extend within the shaped rebar.

6 . The method according to claim 1 , further comprising supporting the framework on at least one base supported on a ground surface.

7 . The method according to claim 6 , wherein the building of the mold comprises:
installing upper inner forms over upwardly facing portions of the framework and adjacent the functional components; installing lower inner forms in a region between the framework and the ground surface, lower supports being located adjacent the lower inner forms, wherein the rebar is supported on the lower supports; and installing outer forms over lateral sides of the track section shape of the rebar.

8 . The method according to claim 7 , wherein, after removing the mold, the completed track section is supported on the framework and the lower supports, and the method further comprises:
lifting the completed track section from the framework and the lower supports; sliding, in a longitudinal direction, the completed track section relative to the framework and the lower supports; and removing the upper inner forms from an interior of the completed track section.

9 . The method according to claim 1 , wherein the framework comprises a first alignment fixture and a second alignment fixture, and the method further comprises supporting the first alignment fixture on a bottom tool form,
wherein the bottom tool form includes a plurality of tool locating post holes and a plurality of pitch locating post holes, into which a plurality of tool locating posts and a plurality of pitch locating posts are inserted, wherein the first alignment fixture comprises holes to receive the plurality of tool locating posts and the plurality of pitch locating posts and component receivers for retaining the at least some of the functional components to be arranged parallel to each other in the common plane, wherein the first alignment fixture is supported above the rebar and the method further comprises positioning and aligning the at least some of the functional components, whereby the at least some of the functional components are arranged parallel to each other in the common plane.

10 . The method according to claim 9 , wherein the building of the mold comprises installing lower forms over longitudinal ends of the bottom form tool;
wherein the dispensing of the binder material comprises dispensing the binder material to a level covering anchors of the at least some functional components and below the at least some functional components; and wherein the at least some functional components comprise a levitation rail and braking rails.

11 . The method according to claim 10 , wherein, after a first predetermined curing period, the method further comprises:
removing the first alignment fixture from the bottom tool form; supporting the second alignment fixture on the tool locating posts; and coupling the at least some other functional components to the second alignment fixture in the first lateral plane normal to the common plane.

12 . The mold according to claim 11 , wherein the building of the mold further comprises installing a first intermediate form above a first lateral edge of the bottom tool form and above the lower form in a region of the first lateral edge of the bottom tool form, and
wherein the dispensing of the binder material further comprises dispensing the binder material to cover anchors of intermediate ones of the at least some other functional components and to provide a lateral separation between the intermediate ones of the at least some other functional components and the dispensed binder material; and wherein the intermediate ones of the at least some other functional components comprise a propulsion rail.

13 . The method according to claim 12 , wherein, after a second predetermined curing period, the building of the mold further comprises installing an first upper form above the first intermediate form, and
wherein the dispensing of the binder material further comprises dispensing the binder material to cover anchors of upper ones of the at least some other functional components and to provide a lateral separation between from the upper ones of the at least some other functional components and the dispensed binder material; and wherein the upper ones of the at least some other functional components comprise a guidance rail.

14 . The method according to claim 13 , wherein, after a third predetermined curing period, the method further comprises:
removing the second alignment fixture from the bottom tool form and from the at least some other functional components; rotating the second alignment fixture and supporting the second alignment fixture on the tool locating posts; and coupling the at least still other functional components to the second alignment fixture in the second lateral plane normal to the common plane and parallel to the first lateral plane.

15 . The mold according to claim 14 , wherein the building of the mold further comprises installing a second intermediate form above a second lateral edge of the bottom tool form and above the lower form in a region of the second lateral edge of the bottom tool form, and
wherein the dispensing of the binder material further comprises dispensing the binder material to cover anchors of intermediate ones of the at least still other functional components and to provide a lateral separation between the intermediate ones of the at least still other functional components and the dispensed binder material; and wherein the intermediate ones of the at least still other functional components comprise a propulsion rail.

16 . The method according to claim 15 , wherein, after a fourth predetermined curing period, the building of the mold further comprises installing an second upper form above the second intermediate form, and
wherein the dispensing of the binder material further comprises dispensing the binder material to cover anchors of upper ones of the at least still other functional components and

Assignees

• Hansl Mario
• Williams Grahme
• Ferm Jett
• Hyperloop Tech Inc

Inventors

• Hansl Mario
• Williams Grahme
• Ferm Jett

Classifications

• B28B23/02

  wherein the elements are reinforcing members {(B28B23/0006 takes precedence)} · CPC title

• B60L13/04

  Magnetic suspension or levitation for vehicles · CPC title

• E01B37/00 Primary

  Making, maintaining, renewing, or taking-up the ballastway or the track, not provided for in a single one of groups E01B27/00 - E01B35/00 · CPC title

• E01B25/305 Primary

  Rails or supporting constructions · CPC title

• B61B13/08

  Sliding or levitation systems (vehicles with air cushions between rails and vehicles B60V3/04) · CPC title