A system for fastening a rail on a substrate includes a base plate, molded into which is a central portion, the width of which is adapted to the width of the rail foot of the rail to be fastened, with at least one fastening element for connecting the base plate to the substrate. The at least one tensioning element is provided for holding down the rail on the base plate. The system provides a fastening system allowing fastening of rails that satisfies modern requirements with the additional benefit of low production costs and simple assembly, while maintaining the basic configuration of the base plate provided and using simple means.

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of and priority to German Patent Application No. DE 10 2007 045 466.1-25, filed on Sep. 21, 2007, which is owned by the assignee of the instant application. The disclosure of this application is incorporated herein by reference in its entirety. 
       FIELD OF THE INVENTION 
       [0002]    The invention relates to a system for fastening a rail on a substrate, with a base plate, molded into which is a depressed central portion, the width of which is adapted to the width of the rail foot of the rail to be fastened, with at least one fastening element for connecting the base plate to the substrate and with at least one tensioning element provided for holding down the rail on the base plate. 
       BACKGROUND 
       [0003]    Systems of this type are used in particular to fasten rails on a wooden sleeper in a simple manner. The purpose of the base plate, which is generally made of a steel as a hot-rolled or forged product, is in this case to transmit uniformly onto the sleeper the loads which occur when a railway vehicle travels over the fastening point formed by such a system. In order to ensure rapid and at the same time particularly simple assembly, the base plates are fastened on a wooden sleeper during assembly conventionally with nails. The rail is also fastened on the base plate generally with nails which are struck through corresponding openings molded in the base plate. The nail head has in this case a portion protruding laterally relative to its shank. When it is struck into the wooden sleeper, the nail head is oriented in such a way that it rests, when fully struck in, on the rail foot and holds down the rail. 
         [0004]    Fastening systems of the type described hereinbefore fulfil their purpose in track installations on which trains travel at a comparatively low speed. However, they do not meet the requirements of modern high-speed trains. 
         [0005]    A large number of fastening systems which are able reliably to accommodate the dynamic loads occurring in high-speed trains are known. A typical example of a system of this type is offered by the Applicant under the name “System KS”. Information about and an installation guide for this system are available from the URL “www.vossloh-fastening-systems.de”. 
         [0006]    The System KS has a base plate which is made of steel and is also referred to by experts as a “rib plate”. The base plate has a central portion which is laterally delimited by a respective rib. The distance between the ribs corresponds in this case to the width of the rail foot of the rail to be fastened. A respective opening, positioned in which is a screw bolt, the threaded portion of which points away from the upper side of the respective rib, is molded into the ribs from the free upper side thereof. In addition, through-openings, through which the screws, which serve as fastening elements, can be screwed into the respective substrate, are molded into the base plate. 
         [0007]    In the System KS, the holding forces required in order securely to hold the rail are generated by means of W-shaped tensioning clamps, each of which is mounted on one of the ribs. The loop-shaped central portion of the tensioning clamps is in this case placed around the threaded portion of the screw bolt inserted into the respective rib and braced against the base plate by means of a nut screwed onto the screw bolt. In this case, the spring arms of the tensioning clamp are supported with their free ends on the rail foot and thus resiliently hold down the rail. The resilient holding brought about in this way of the rail has the advantage that the fastening has a defined flexibility. This ensures that the rail is not excessively loaded even under the action of high dynamic forces. 
       SUMMARY OF THE INVENTION 
       [0008]    In general, in one aspect, the invention provides a fastening system allowing, fastening of rails that satisfies modern requirements with beneficial production costs and simple assembly, while maintaining the basic configuration of the base plate provided and using simple means. 
         [0009]    The fastening system according to the invention comprises a base plate. This base plate has a central portion, the bottom of which is lowered relative to the surface of the remaining portions of the base plate. The width of the central portion, measured transversely to the longitudinal direction of the rail to be fastened, is in this case adapted to the width of the rail foot of the rail to be fastened. Furthermore, the system according to the invention comprises at least one fastening element which is intended for connecting the base plate to the substrate and also at least one tensioning element provided for holding down the rail on the base plate. 
         [0010]    In order to be able to continue using the above-listed basic components, which have already proved broadly successful in practice, and at the same time to allow fastening of the rail that is easily able to accommodate the loads which occur in modern high-speed railway traffic, the invention proposes moulding an opening into the base plate, which opening emanates from the upper side thereof associated with the rail, leads to the underside thereof associated with the substrate and has a non-circular cross-sectional shape. 
         [0011]    According to the invention, the tensioning element is to be guided through this opening, starting from the underside of the base plate associated with the solid substrate. The tensioning element has, in the manner of a machine screw, a shank, a head which is formed integrally with the shank and the diameter of which is larger than the diameter of the shank, and a transition portion formed between the head and shank. The crucial thing is that the cross-sectional shape and dimensions of this transition portion are adapted to the shape and dimensions of the opening in the base plate in such a way that the transition portion is positioned, when introduced into the opening, in the opening so as to be prevented from rotating by a form fit. This allows the shank, which is guided through the opening, of the fastening element to protrude freely and non-rotatably beyond the free upper side of the base plate and thus to be used for bracing a spring element against the base plate. 
         [0012]    This spring element can in this case be configured in a manner known per se. It accordingly has a spring arm which, when the spring element is braced against the base plate, exerts a resilient holding-down force onto the rail foot. For this purpose, the spring arm can press in a manner known per se with its free end portion onto the foot of the rail to be fastened. 
         [0013]    The invention thus provides a fastening system which not only allows the base plate which is known in the art and has proven successful in practice to continue to be used, but rather in addition also allows a likewise known spring element to be used for resiliently supporting the rail. In this case, the rail is fastened in a manner which ensures that the rail can yield even to forces occurring in high load mode with a resilience which ensures that the rail is subjected to significantly reduced wear, compared to the prior art, even when used for a long time. 
         [0014]    In a system according to the invention, the tensioning element is prevented from becoming lost as a result of the fact that it is introduced into the opening in the base plate from the underside, and the head, the diameter of which is larger than the diameter of the transition portion at least in certain portions, is supported at the underside of the base plate. When the fastening system is fully assembled, i.e. when the base plate is placed onto the substrate, the substrate accordingly covers the screw head. In order to ensure that the screw head does not prevent the base plate from lying on the substrate over its entire area, a correspondingly formed depression can be molded into the substrate. However, with regard to the possibility of preassembly, it is particularly advantageous if the opening associated with the tensioning element merges, on the underside of the base plate associated with the substrate, with a depression, the cross-sectional shape and dimensions of which are adapted to the shape of the head of the tensioning element in such a way that the head of the tensioning element is positioned in the depression when the tensioning element is inserted into the respective opening in the base plate from the underside. The dimensions of the depth of the depression are in this case preferably such that the head of the tensioning element is positioned completely in the depression when the system is fully assembled. 
         [0015]    The form fit which prevents the tensioning element from rotating can be formed as a result of the fact that the transition portion of the tensioning element has a cross-sectional shape with at least one distinct corner. In terms of production, this can be achieved in a particularly simple manner, for example, when the transition portion of the tensioning element has a quadrilateral cross section. 
         [0016]    If the system according to the invention is to be delivered preassembled to the construction site, it can be beneficial if an interference fit is superimposed on the form fit of the transition portion in the opening associated with the tensioning element. An interference fit of this type can for example be achieved as a result of the fact that the diameter of the opening in question is slightly smaller than the transition portion of the tensioning means. 
         [0017]    The self-centering of the tensioning means in the depression can be assisted as a result the fact that the head of the tensioning element is configured so as to run obliquely in the direction of the transition portion. 
         [0018]    A particularly simple possibility for bracing the spring element on the base plate is obtained when an outer thread is molded, starting from its free end, into the shank of the tensioning element and a nut, which can be screwed onto the outer thread, is provided for tensioning the spring element. 
         [0019]    The possibility of using spring elements which are known per se and have proven broadly successful in practice also in a system according to the invention can additionally be extended as a result of the fact that there is provided a guide plate which can be laid onto the base plate and has a recess, through which the shank of the tensioning element can be inserted, and at its free upper side, which is remote from its underside associated with the base plate, a shaped element for guiding at least a portion of the spring element supported on the base plate. The guide plate thus shaped can be used to support the spring element in such a way that it substantially maintains its basic shape even when deformed and thus transmits maximum holding forces onto the rail via its spring arms. 
         [0020]    Conventionally, the known base plates have on their upper side rib shoulders which are arranged adjoining the central portion and extend parallel to the longitudinal direction of the rail to be fastened. These rib shoulders prevent the rail from moving out of the lowered central portion, when vehicles travel over said rail, as a result of transverse forces which occur. The shape of the transition between the respective rib shoulder and the side portion laterally adjoining said rib shoulder on the side remote from the central portion is generally not unambiguously configured and is subject to high production inaccuracies. Thus, it can be configured in a groove-like, step-like or other manner. 
         [0021]    In order nevertheless to ensure, even in base plates provided with rib shoulders, positionally secure and permanently constant supporting of the guide plate, according to a further particularly practical configuration of the invention, an, in particular web-like, projection, via which the guide plate is supported on the respective rib shoulders when the system is fully assembled, is formed on the underside of the guide plate. As a result of the fact that it is supported via the web, the area of contact between the guide plate and the respective rib shoulder is reduced to a minimum. As a result of the fact that supporting of the guide plate over the entire area is purposefully dispensed with, the shape of the ribs and the shape of their transition to the adjoining side portion accordingly have no influence on the position which the guide plate assumes. 
         [0022]    Particularly secure and simple positioning of the guide plate can be ensured as a result of the fact that, according to the invention, the recess in the guide plate is formed as an opening surrounded by the material of the guide plate. 
         [0023]    A further variation of the invention that is particularly beneficial for practical application is characterized in that two projections, which are arranged set apart from each other and are intended laterally to surround one of the fastening elements intended for connecting the base plate to the substrate, are configured at a portion of the guide plate. The projections laterally adjoining the respective fastening element prevent, in the simplest manner conceivable, the guide plate from rotating without requiring for this purpose shaped elements which are complex to produce at the base plate or additional fastening parts. 
         [0024]    The base plate used and configured in accordance with the invention can also, like the known base plates of the type specified at the outset, have openings for guiding through the fastening elements provided in each case for connecting the base plate to the substrate. In order on the one hand to ensure that the connection between the substrate and the base plate is produced at a particularly beneficial position and on the other hand to be able to use the respective fastening element for fixing the position of the guide plate, it is in this case expedient if the center points of the opening associated with the tensioning element and an opening associated with one of the fastening elements are jointly arranged on a straight line which is oriented transversely to the longitudinal direction of the rail to be fastened. 
         [0025]    If a second fastening element is required for fastening the base plate on the solid substrate, an opening can be molded into the base plate for this element too. Specifically when the solid substrate is made of wood or a material having a similarly fibrous structure, the risk of splitting of the sleeper by the pressure exerted by the respective fastening element when screwed in can be avoided as a result of the fact that the center point of the opening provided for the second fastening element is arranged on a straight line which extends parallel to the longitudinal direction of the rail to be fastened and intersects the connecting line between the center points of the opening for the first fastening element and the opening of the tensioning element at a point lying between these two center points. 
         [0026]    Typically, in fastening systems according to the invention as in the prior art, the rail is held in each case on both sides by corresponding tensioning elements. Accordingly, in a system according to the invention too, at least one opening for a tensioning element and at least one opening for a fastening element will regularly be molded into the side portions of the base plate that adjoin the central portion on both sides. Insofar as the openings molded in accordance with the invention into the base plate are in this case arranged toward the center of the width of the base plate, it is beneficial, in order to simplify positionally correct assembly, to arrange the openings of the two side portions point-symmetrically. 
         [0027]    In principle, it is possible to use nails or other fastening elements which can be driven into the respective solid substrate by being struck also for connecting the base plate used in a system according to the invention. Particularly operationally reliable fastening is however obtained when the fastening elements are screws. If the solid substrate is formed by wooden sleepers, these screws can either be configured as self-tapping screws or be screwed into correspondingly preshaped openings. If the system according to the invention is provided for fastening a rail on a substrate formed by concrete sleepers or plates, dowels, into which the fastening screws provided in accordance with the invention are then screwed, can be inserted into this substrate in a manner also known per se. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0028]    The invention will be described hereinafter in greater detail with reference to drawings which illustrate an exemplary embodiment and in which: 
           [0029]      FIG. 1  is a cross section of a system for fastening a rail on a wooden sleeper; 
           [0030]      FIG. 2  is a plan view of the system according to  FIG. 1 ; 
           [0031]      FIG. 3  is a lateral view of a tensioning element used in  FIGS. 1 and 2 ; 
           [0032]      FIG. 4  is a plan view of a guide plate used in  FIGS. 1 and 2 ; and 
           [0033]      FIG. 5  is a longitudinal section of the guide plate. 
       
    
    
     DESCRIPTION 
       [0034]    The system  1  for fastening a rail  2  on a wooden sleeper  3  comprises a conventionally shaped base plate  4  into which a central portion  5  extending over the entire width B of the base plate  4  is molded. 
         [0035]    The bottom  6  of the central portion  5  is lowered relative to the adjoining free surface  7  of the side portions  8 ,  9  of the base plate  4  adjoining the central portion  5  on both sides, so that the central portion  5  is laterally delimited by rib shoulders  10 ,  11  likewise extending over the entire width B of the base plate  4  in the longitudinal direction L of the rail  2 . 
         [0036]    The rib shoulders  10 ,  11  pass in a groove-like transition  12  into the region of the side portions  10 ,  11  adjoining them on the side remote from the central portion  5 . The transition  12  has in this case no defined shape and can differ from base plate to base plate. A respective first opening  13 ,  14 , which is arranged in the close vicinity of the respective rib shoulder  10 ,  11 , is molded into the side portions  10 ,  11  of the base plate  4 . The openings  13 ,  14  lead in this case from the upper side  7  of the side portions  10 ,  11  to the underside  15  of the base plate  4  associated with the sleeper  3 . 
         [0037]    In the direction of the underside  15  of the base plate  4 , the openings  13 ,  14  merge in each case with depressions  16 ,  17  molded into the base plate  4  from the underside  15 . The inner surfaces of the depressions  16 ,  17  run in this case conically toward one another in the direction of the respective opening  13 ,  14 . 
         [0038]    The openings  13 ,  14  have in each case a square cross-sectional shape in which one corner is positioned next to the respective rib shoulder  10 ,  11 , so that the side surfaces of the respective opening  13 ,  14  running toward this rib shoulder  10 ,  11  are oriented at an angle of approx. 45° relative to the respective contact surface  19  of the rib shoulders  10 ,  11  associated with the rail foot  18 . 
         [0039]    A tensioning element  20 ,  21  configured in the manner of a screw is respectively positioned in each of the openings  13 ,  14 . The tensioning elements each have a shank  22 , a transition portion  23  adjoining the shank  22 , and a head  24  formed integrally with the transition portion  23 . The head  24  has a cross section which is circular, when viewed from above, and the diameter of which is larger than the largest diameter of the transition portion  23 . The largest diameter thereof is again larger than the diameter of the shank  22  which is also circular in cross section. 
         [0040]    The circumferential surface of the head  24  of the tensioning elements  20 ,  21  tapers in the direction of the transition  23  at a gradient which is adapted to the gradient of the inner surfaces of the depressions  16 ,  17 . At the same time, the depth of the depressions is adapted to the height of the head  24  of the tensioning elements  20 ,  21 , so that the head  24  are each oriented with their head side  25 , when the tensioning element  20 ,  21  is inserted fully into the respective opening  13 ,  14 , flush with the underside  15  of the base plate  4 . 
         [0041]    The shape and dimensions of the cross section of the transition portion  23  of the tensioning elements  20 ,  21  are adapted to the shape and the dimensions of the openings  13 ,  14  in such a way that the respective tensioning element  20 ,  21  can be inserted into the associated opening  13 ,  14  with slight play and is non-rotatably held, when fully inserted into the opening  13 ,  14 , by a form fit with respect to rotation about the longitudinal axis of the respective tensioning element  20 ,  21 . 
         [0042]    An outer thread  26  is molded into the shank  22 , starting from the free end thereof. 
         [0043]    A respective guide plate  27 ,  28  is laid onto the upper side  7  of the side portions  8 ,  9 . The guide plates  27 ,  28  are made of a plastics material and each have a recess  29  formed as a through-opening surrounded by the material of the respective guide plate  27 ,  28 . In the assembled state illustrated in  FIGS. 1 and 2 , the shank  22  of the respective tensioning element  20 ,  21  is guided through this recess  29 . 
         [0044]    The recess  29  is molded into a first portion  30  of the guide plates  27 ,  28  that passes into a second portion  31  which is wider in its configuration than the first portion  30 . The planar free end face  32  of the first portion  30  of the guide plates  27 ,  28  is associated with the rail foot  8 . 
         [0045]    A shaped element  33 , which is deepened in the manner of a channel, is molded into the upper side of the second portion  31 , adjoining the first portion  30  of the guide plates  27 ,  28 . In addition, two projections  34 , which point diametrically away from the end face  32  and laterally surround a recess  35  in a U-shaped manner, are configured at the second portion  31 . 
         [0046]    At the underside  36  of the guide plates  27 ,  28 , a web-like projection  37 , which extends parallel to the end face  32  and intersects the opening  9 , is configured in the region of the first portion  30 . 
         [0047]    A further web-like projection  38 , also extending parallel to the end face  32 , is shaped in the region of the second portion  31  of the guide plates  27 ,  28  below the shaped element  33 . 
         [0048]    In the assembled state shown in  FIGS. 1 and 2 , the guide plates  27 ,  28  are supported on the upper side  7  of the base plate  4  via their web-like projections  37 ,  38 . The projection  37  rests in this case on the rib shoulder  10 ,  11  associated with the respective guide plate  27 ,  28 . In this way, the respective transition  12  is bridged, so that the respective guide plate  27 ,  28  rests on the base plate  4  in all cases in a positionally secure manner, irrespective of the shape of the transition. 
         [0049]    In the assembled state, a fasting element  39 ,  40  configured as a screw is positioned with its screw head  41  in the recess  35  in the guide plates  27 ,  28 . The fastening elements  39 ,  40  are screwed into the wooden sleeper  3  in each case by a further opening  41 ,  42  molded into the base plate  4 . The center point M 1  of the openings  41 ,  42  lies in this case on a straight line X which extends through the center point M 2  of the opening  13 ,  14  respectively associated therewith and is oriented, viewed from above ( FIG. 2 ), transversely to the longitudinal direction L of the rail  2  to be fastened. 
         [0050]    The openings  13 ,  41  of the side portion  8  and the openings  14 ,  42  of the side portion  9  are each arranged in one half of the respective side portion  8 ,  9 . In addition to the fastening by the fastening elements  39 ,  40 , the respective side portions  8 ,  9  are each connected to the wooden sleeper  3  via a further, likewise screw-like fastening element  43 ,  44 . The additional fastening elements  43 ,  44  are in this case each guided through an opening (which cannot be seen here) formed in the respective other half of the side portions  8 ,  9 . 
         [0051]    The center point M 3  of this opening lies in this case on a straight line Y which is oriented perpendicularly to the straight line A and, viewed from above ( FIG. 2 ), intersects said straight line A between the center points M 1 , M 2 . This arrangement minimizes the risk of the wooden sleeper  3  splitting as a result of the forces exerted by the fastening elements  39 ,  40 ,  43 ,  44 . 
         [0052]    The openings  13 ,  41  with the opening for the additional fastening element  43  of the side portion  8  are positioned point-symmetrically to the openings  14 ,  42  with the opening for the additional fastening element  44  of the side portion  9 . 
         [0053]    A respective spring element  45 ,  46 , which is a conventional commercial tensioning clamp shaped in the shape of a W, is supported on the guide plates  27 ,  28 . The spring elements  45 ,  46  are in this case oriented in such a way that their central loop  47  is guided around the shank  22  of the tensioning element  20 ,  21  respectively associated with said spring elements, and the regions of transition from the central loop  47  to the portions  50 ,  51  leading to the spring arms  48 ,  49  formed integrally therewith are positioned in the channel-like shaped element  33  of the respective guide plate  27 ,  28 . In the fully assembled state (shown on the right-hand side in  FIGS. 1 ,  2 ), the spring arms  48 ,  49  of the spring elements  45 ,  46  rest with their free ends on the rail foot  18  and resiliently load said rail foot with the required holding-down force. In the preassembled state (shown on the left-hand side in  FIGS. 1 ,  2 ), the respective spring element  45 ,  46  is slid away from the central portion  5  sufficiently far that the end of the spring arms  48 ,  49  rests on the respective rib shoulder  10 ,  11  and the rail  2  can be placed into the central portion  5  unimpeded. 
         [0054]    The spring elements  45 ,  46  are braced against the base plate  4  in this case via a respective nut  52 ,  53  which is screwed onto the shank  24  of the respective tensioning element  20 ,  21 . 
       REFERENCE NUMERALS 
       [0000]    
       
           1  System for fastening the rail  2   
           2  Rail 
           3  Wooden sleeper 
           4  Base plate 
           5  Central portion of the base plate  4   
           6  Bottom of the central portion  5   
           7  Surface of the side portions  8 ,  9   
           8 ,  9  Side portions 
           10 ,  11  Rib shoulders 
           12  Transition 
           13 ,  14  Openings in the base plate  4   
           15  Underside of the base plate  4   
           16 ,  17  Depressions 
           18  Rail foot 
           19  Contact surface 
           20 ,  21  Tensioning elements 
           22  Shank of the tensioning elements  20 ,  21   
           23  Transition portion of the tensioning element  20 ,  21   
           24  Head of the tensioning elements  20 ,  21   
           25  Free head side of the tensioning element  20 ,  21   
           26  Outer thread of the shank  24   
           27 ,  28  Guide plates 
           29  Recess in the guide plates  27 ,  28   
           30  First portion of the guide plates  27 ,  28   
           31  Second portion of the guide plates  27 ,  28   
           32  Planar free end face of the first portion  30   
           33  Shaped element 
           34  Projections 
           35  Recess 
           36  Underside of the guide plates  27 ,  28   
           37 ,  38  Projections 
           39 ,  40  Fastening elements 
           41 ,  42  Openings in the base plate  4   
           43 ,  44  Additional fastening elements 
           45 ,  46  Spring elements 
           47  Central loop of the spring element  45   
           48 ,  49  Spring arms of the spring element  45   
           50 ,  51  Portions of the spring element  45   
           52 ,  53  Nuts 
         B Width of the base plate  4   
         L Longitudinal direction of the rail  2   
         M 1  Center point of the opening  42   
         M 2  Center point of the opening  14   
         M 3  Center point of the opening in the fastening elements  43 ,  44   
         X Straight line 
         Y Straight line