Rail Vehicle Electrical Contact Coupling With Interlocking Flaps
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Solution Overview
Problem
Conventional electrical contact couplings for rail vehicles face issues with unreliable opening and closing of protective flaps due to damage from debris, complex attachment requirements, and high costs associated with additional elements, especially under extreme weather conditions.
Innovation Solution
An electrical contact coupling for rail vehicles featuring positive locking elements on the protective flap, which are integrally formed and designed to interact with complementary elements on a mating coupling, allowing for synchronous opening without additional actuating devices, ensuring reliable operation even under extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rubber elements are attached to the protective flap to increase friction and prevent slippage, then the synchronous opening is improved, but the device complexity and manufacturing costs increase due to additional attachment requirements
Solution Approach 1:
The positive locking elements are integrated directly into the protective flap structure, merging the locking function with the flap itself. This eliminates the need for separate rubber elements and their attachment mechanisms, reducing device complexity while maintaining synchronous opening reliability through the interlocking geometry of the positive locking elements.
Solution Approach 2:
The positive locking elements on the protective flap automatically engage with complementary elements on the mating coupling without requiring additional actuating devices or external components. The structure itself provides the locking and friction functions, making the system self-sufficient and reducing overall complexity.
2Ease of operation
If spring devices are exposed on the housing for actuating the protective flap, then the operation is simplified, but the reliability decreases due to damage from flying gravel or debris
Solution Approach 1:
The spring device is nested within the housing structure, with the spring element positioned inside a recess or cavity in the housing. This protects the spring from external debris and damage while still allowing it to function for actuating the protective flap. The spring remains concealed rather than exposed, eliminating the vulnerability to flying gravel.
3Reliability
If the protective flap is curved around several axes, then the coverage and protection are improved, but the manufacturing complexity increases due to difficult attachment requirements
Solution Approach 1:
The positive locking elements are integrated directly into the curved protective flap structure, merging the complex geometry with the locking function. This allows the curved shape to be manufactured as a single piece or pre-formed component, eliminating the need for separate attachment steps for friction elements on complex surfaces.
Solution Approach 2:
The positive locking elements are designed with specific geometric parameters that complement each other on mating couplings. By optimizing the shape, size, and position of these elements, the curved protective flap achieves reliable engagement without requiring additional attachment processes, even on complex multi-axial surfaces.
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 enables trouble-free, synchronous opening and closing of protective flaps, reducing costs and maintaining functionality under various weather conditions, while being reversible and adaptable to different orientations.
Implementation Method 1
the rolling zone has positive locking elements for forming a positive locking effect in at least one direction of the travel path of the protective flap when interacting with positive locking elements of a mating electrical contact coupling
Data Source
Figure 1~2a
Figure 2b~3
Figure 4a~5b
AI summary
The invention relates to an electrical contact coupling (1) for an automatic middle buffer coupling (2) of a rail vehicle, comprising a housing (10) in which an interface unit (12) with a plurality of connection elements (14) is arranged, a protective flap (16) for covering an access point (18) to the connection elements (14) of the interface unit (12), and an actuating device, which is connected to the protective flap (16), for moving the protective flap (16) between a first position (P1), in which the protective flap (16) covers the access point, and a second position (P2), in which the protective flap (16) clears the access point (18), wherein at least one rolling zone (19.1, 19.2, 19.11, 19.12, 19.13, 19.21, 19.22, 19.23) for interacting with a rolling zone of a mating electrical contact coupling (1') is arranged on the end-side surface (17) of the protective flap (16), wherein the individual rolling zone (19.1, 19.2, 19.11, 19.12, 19.13, 19.21, 19.22, 19.23) has interlocking elements (25.1, 25.2) for forming an interlocking connection, which acts at least in one direction of the movement travel of the protective flap (16), upon interacting with interlocking elements of a mating electrical contact coupling (1') which are designed in a complementary manner with respect to the interlocking elements (25.1, 25.2) of the electrical contact coupling.