Deformation Bolt Energy Absorption for Compact Impact Loads
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Solution Overview
Problem
Existing energy absorption devices in train couplers, such as shear out elements and deformation tubes, are inadequate in managing exceptional loads during impacts, leading to incomplete energy absorption and potential damage to structures and passengers.
Innovation Solution
A method and device utilizing a semi-solid or solid deformation bolt made of cold-forming material with a taper section seated in a hard metal ring, which undergoes controlled diameter reduction during elongation to absorb energy, providing a continuous energy absorption capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional shear out elements or deformation tubes are used for energy absorption, then the device structure is simple, but the energy absorption capacity is insufficient and damage occurs
Solution Approach 1:
The patent changes the material state parameter from solid to semi-solid, enabling continuous deformation and energy absorption. The semi-solid material allows controlled diameter reduction during elongation, providing continuous energy absorption capacity throughout the deformation stroke, unlike traditional solid materials that fracture abruptly
Solution Approach 2:
The patent uses composite construction combining semi-solid material with cold-forming material properties. This composite approach integrates the energy absorption capability of semi-solid materials with the structural integrity and deformability of cold-forming materials, achieving superior energy absorption while maintaining structural functionality
2Loss of energy
If deformation tubes with radial collapse are used, then energy absorption occurs, but the mounting space requirement is large
Solution Approach 1:
The patent changes the deformation mode from radial collapse to controlled diameter reduction during elongation. This parameter change enables energy absorption within a more compact volume, as the deformation occurs along the length of the bolt rather than requiring radial expansion space
Solution Approach 2:
The patent transitions the deformation mechanism from two-dimensional radial collapse to one-dimensional elongation with concurrent diameter reduction. This dimensional shift allows energy absorption to occur primarily along the longitudinal axis, reducing the radial space requirements and enabling more compact mounting
3Loss of energy
If cold-forming material with taper section is used, then continuous energy absorption is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes controlled parameter changes during deformation, where the semi-solid material's flow behavior allows gradual diameter reduction. This controlled parameter change enables continuous energy absorption while the taper section geometry provides a predictable deformation pattern that can be manufactured with standard tolerances
Solution Approach 2:
The patent applies local quality by creating a taper section with specific geometric properties in the cold-forming material. This localized geometric feature concentrates the deformation in a controlled manner, ensuring continuous energy absorption while the rest of the component maintains standard manufacturing tolerances
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 solution effectively absorbs energy during impacts, reducing damage by allowing for continuous energy absorption throughout the deformation stroke, minimizing mounting space, and ensuring precise installation, thus enhancing safety and versatility.
Implementation Method 1
energy is absorbed in the process of deformation of an element or elements which are put under stress from the objects upon impact
Implementation Method 2
a semi-solid or solid deformation bolt made of cold-forming material with a taper section adapted to be seated in a through hole that is formed in a hard metal ring
Data Source
AI summary
An energy absorption device absorbs energy that is released upon impact between two objects in relative motion. An exceptional load applied to any of the two objects results in acceleration of one object relative to the other object. The acceleration energy is absorbed by deformation of an element or elements that are put under stress from the objects upon impact. The process of deformation includes a controlled diameter reduction during a forced elongation of a semi-solid or solid deformation bolt made from a cold-formed material in the direction of force generated from the acceleration.