Coupler-Mounted Trainline Support Casting for Brake Hose Positioning
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Solution Overview
Problem
The existing trainline brake system for rail cars faces challenges in maintaining a consistent distance between the trainline support casting and the coupler, leading to potential brake failure due to hose kinking or uncoupling, and existing mounting solutions are not adaptable to variations in coupler head designs, interfering with other essential components.
Innovation Solution
A trainline support casting capable of partial rotational movement in a horizontal plane, combined with a bracket mounted directly on the coupler, allowing adjustable positioning and interference-based key pocket system to maintain the required distance and angle, ensuring reliable hose connection and disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bracket is mounted on the yoke of a cushioned unit or to the underbody of a rail car, then the trainline support casting can be supported, but the position of the trainline support casting varies due to slack in various components
Solution Approach 1:
The mounting system is divided into distinct segments: the bracket mounted on the coupler head, the trainline support casting, and the hose assembly. This segmentation allows each component to be optimized independently and reduces the cumulative effect of slack and variation throughout the system.
Solution Approach 2:
The bracket serves as an intermediary component that directly connects the trainline support casting to the coupler head. By positioning the bracket at this strategic location with direct mounting holes, it acts as a stable mediator that eliminates the slack and variation problems associated with mounting on the yoke or underbody.
2Adaptability or versatility
If the distance from the trainline support casting to the end of the coupler is set according to AAR standard, then uniform hoses can be used throughout the United States, but hose kinking may occur if the span distance is too short or uncoupling if the distance is too great
Solution Approach 1:
The trainline support casting is designed with rotational capability, allowing it to dynamically adjust its position and angle. This dynamic adjustment ensures that the hose span length remains optimal under various operating conditions, preventing both kinking and uncoupling while maintaining compatibility with standard hoses.
Solution Approach 2:
The system allows for parameter changes in the position and orientation of the trainline support casting through rotational movement. By changing these parameters, the effective span length of the hose can be optimized for different coupling positions and angles, maintaining reliability across varying conditions.
3Ease of manufacture
If the bracket is positioned far to the right of the coupler, then the trainline support casting can be mounted, but it interferes with the angle cock valve on most current cushioned car designs
Solution Approach 1:
The bracket is designed with an asymmetric configuration where the mounting holes are positioned to the left of the coupler head rather than to the right. This asymmetric placement strategically avoids interference with the angle cock valve while maintaining ease of manufacture and proper functionality.
4Strength
If all four conventionally provided openings on the coupler head are used for mounting the bracket, then the bracket can be securely mounted, but it prohibits the mounting of an end-of-train device which conventionally uses two of the apertures
Solution Approach 1:
The bracket design extracts only the necessary two mounting holes from the coupler head, rather than requiring all four openings. This selective use of mounting points provides sufficient security for the bracket while leaving the remaining openings available for end-of-train device mounting, thus maintaining compatibility with existing conventions.
Data Source
AI summary
A trainline support casting is provided to support flexible brake hoses between adjacent rail cars. The trainline support casting is capable of partial rotational movement during use and is supported on a mounting bracket adapted to mount directly to a coupler head of a cushioned car coupler, insuring a constant distance from the end of the coupler to the trainline support casting and a constant distance of the brake hoses above the ground according to AAR standards.