Cross-Connector Electrical Contact Coupling for Rail Vehicles
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Solution Overview
Problem
Conventional electrical contact couplings for rail vehicles require a large number of lines to connect individual contacts, leading to increased complexity, size, and maintenance challenges, as well as higher manufacturing costs and a higher risk of interference.
Innovation Solution
The introduction of a cross connector, preferably a multi-layer printed circuit board, that pairs upper and lower contacts with corresponding contacts on a mating coupling, reducing the number of lines needed and allowing for a more compact design by enabling electrical or optical connections between contacts via a single component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual lines are used to connect each contact in conventional electrical contact couplings, then reliable electrical connection is achieved, but the number of lines increases significantly leading to increased complexity and size
Solution Approach 1:
The patent combines multiple individual contact connections into a single cross connector component that establishes electrical connections between upper and lower contact banks simultaneously. This merging approach reduces the number of separate lines while maintaining reliable electrical contact through the integrated cross connector design.
Solution Approach 2:
The cross connector serves multiple functions: it connects upper contacts to lower contacts, provides structural support for the contact banks, and enables bidirectional electrical signal transmission. This multi-functionality eliminates the need for separate dedicated lines for each contact pair, reducing overall system complexity.
2Adaptability or versatility
If a large number of lines are used to connect contacts, then all contact pairs can be connected, but the size of the electrical contact coupling increases
Solution Approach 1:
Multiple contact connections are merged into a single cross connector assembly that occupies minimal space. The cross connector integrates numerous electrical pathways within a compact structure, allowing comprehensive contact bank connectivity without proportionally increasing the overall coupling volume.
Solution Approach 2:
The cross connector utilizes three-dimensional spatial arrangement to establish electrical connections between upper and lower contact banks. By organizing conductive pathways in multiple dimensions within the cross connector, the design achieves comprehensive connectivity without requiring proportional increases in linear dimensions of the coupling housing.
3Ease of manufacture
If conventional contact coupling designs are used, then standard connectivity is achieved, but manufacturing costs and maintenance complexity increase
Solution Approach 1:
The cross connector combines multiple electrical connection functions into a single manufacturable component that can be produced using standardized processes. This integration reduces the number of separate parts requiring assembly, lowering manufacturing costs while simplifying the overall contact bank structure.
Solution Approach 2:
The contact coupling system is segmented into modular components: upper contact bank, lower contact bank, and cross connector. This segmentation allows each component to be manufactured independently using optimized processes, then assembled into a complete coupling assembly, reducing overall manufacturing complexity and cost.
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
Electrical contact coupling with cross-connectors for track-guided vehicles, preferably rail vehicles, wherein the electrical contact coupling has a coupling housing (1), at least one upper contact bank (2) which is arranged within the coupling housing (1), and at least one lower contact bank (3) which is arranged vertically below the upper contact bank (2) and within the coupling housing (1). The electrical contact coupling also has a contact tongue (4) which is arranged between the upper contact bank (2) and the lower contact bank (3), wherein upper contacts (5) and lower contacts (6) are provided on the contact tongue (4), it being possible for energy and/or signals to be transmitted by means of said contacts from a vehicle, which is connected to the contacts (5, 6) by means of lines, to a mating coupling by means of the contact tongue (4). A cross-connector is provided on at least one contact bank (2, 3) in such a way that the individual contacts (5.1, 5.2,..., 6.1, 6.2,...) of the contact tongue (4) are electrically and/or optically connected, by means of the cross-connector, in pairs to corresponding contacts (5.1', 5.2',..., 6.1', 6.2',...) of a contact tongue (4') of a preferably structurally identical mating coupling in the coupled state of the couplings.