Train Coupler Shear Ring for Controlled Crash Retraction
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Solution Overview
Problem
Current energy dissipation devices in train couplers are inefficient in managing dynamic crash forces and energy absorption, leading to uneven load distribution and partial utilization of stroke lengths, especially in intermediate interfaces, where the foremost dampers are exhausted before the train halts.
Innovation Solution
A shear-off device with a safety ring and shear flange design that allows for controlled fracture and retraction of coupler components, featuring a threaded engagement system and a disc-shaped counterpressure means for energy absorption, enabling linear retraction and redistribution of loads without damaging the housing, and allowing for the reuse and exchange of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional shear-off bolts are used in train coupler mountings, then the coupler components can be sheared off to retract into the deformation tube, but the design is heavy and requires complicated machining operations
Solution Approach 1:
The shear-off device is segmented into distinct functional components: a safety ring with threaded engagement, a shear flange with predetermined fracture plane, and a deformation tube. This segmentation allows each component to be manufactured separately with simpler machining operations while maintaining the overall functionality of the shear-off mechanism.
Solution Approach 2:
The invention extracts the shear-off functionality from conventional complex bolted connections and implements it through a dedicated shear flange component with a predetermined fracture plane. This extraction simplifies the manufacturing process by eliminating complicated machining operations required for traditional shear-off bolts while maintaining the shear-off function.
2Use of energy by moving object
If radial deformation of outer tube is used for energy absorption, then energy can be dissipated through plunger-induced expansion, but the stroke length is limited and energy absorption is not optimized for dynamic crash forces
Solution Approach 1:
The deformation tube is designed to dynamically adapt its deformation characteristics during the crash process. The tube transitions from elastic to plastic deformation in a controlled manner, optimizing energy absorption across different stages of the impact event. This dynamic deformation behavior allows the system to absorb energy more effectively throughout the entire stroke length.
Solution Approach 2:
The invention changes the material and geometric parameters of the deformation tube to optimize energy absorption. The tube's wall thickness, length, and material properties are specifically selected to enable progressive collapse under dynamic load, maximizing energy dissipation while utilizing the full available stroke length.
3Reliability
If foremost dampers are designed for full energy absorption, then they can handle the initial impact, but they are fully exhausted before the train halts while intermediate dampers are only partially used
Solution Approach 1:
The shear-off device enables continuous energy absorption throughout the entire crash process by allowing progressive retraction of coupler components. As the pivot bearing shears off and retracts into the deformation tube, the system maintains energy dissipation capability across multiple crash stages, ensuring that energy absorption continues effectively from initial impact through to complete train halt.
4Stability of the object's composition
If conventional shear-off bolts are used, then the coupler can be sheared off upon impact, but the design does not ensure linear retraction and may cause uneven load distribution
Solution Approach 1:
The shear flange is designed with a predetermined fracture plane and geometric features that guide the shearing action. This preliminary design ensures that when the shear-off occurs, the pivot bearing follows a controlled linear retraction path into the deformation tube, preventing uneven load distribution and ensuring stable energy absorption throughout the process.
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
The shear-off device ensures efficient energy absorption and controlled retraction of coupler components, maintaining the integrity of the housing and allowing for simplified component exchange, effectively managing dynamic crash forces and optimizing energy absorption across the train set.
Implementation Method 1
An inwardly depending shear flange is integrally formed in an opposite rear end of the safety ring, the shear flange reaching in radial direction from the inner periphery towards the centre of the safety ring. The shear flange has a flange base adjoining the inner periphery and a flange point reaching radially inside of the inner periphery of the safety ring.
Implementation Method 2
the inner periphery is formed with a thread for threaded engagement with a supporting structure that is receivable via an open forward end of the safety ring leading to the thread
Data Source
AI summary
A shear-off device for a train coupler comprising a safety ring having an inner periphery formed with a thread for threaded engagement, and further comprising a radially inwards depending shear flange, the shear flange reaching in radial direction from the inner periphery towards the center axis of the safety ring, the shear flange having a flange base adjoining the inner periphery and a flange point reaching radially inside of the inner periphery.