Electromechanical Actuator Play-Free Drive Bearing for Rail Couplers
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Solution Overview
Problem
Existing digital automatic couplings (DAK) for rail vehicles, particularly in freight transport, face challenges with inefficient and time-consuming screw clutches, which require significant personnel and effort. Additionally, the size of electromechanical actuators is not suitable for the narrow construction space of the coupling, leading to suboptimal attachment and increased maintenance needs.
Innovation Solution
The implementation of an electromechanical actuator with a spring pressure brake as a connecting device, which replaces the intermediate flange and provides a play-free drive deposit. This solution allows for a standardized, cost-effective, and robust attachment of the electric motor, effectively managing radial loads and reducing the risk of early failure due to bending moments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an electromechanical actuator is used in the coupling, then the automation and efficiency of the coupling process is improved, but the size of the actuator is not suitable for the narrow construction space of the coupling
Solution Approach 1:
The electric motor is integrated into the actuator housing in a nested arrangement, with the motor positioned within the available space of the coupling mechanism. This nesting approach allows the electromechanical actuator to fit within the narrow construction space while maintaining full automation capabilities.
Solution Approach 2:
The motor brake is designed as a spring-loaded dynamic component that automatically engages and disengages based on operational requirements. This dynamic design allows the brake to provide necessary holding force during coupling while minimizing space requirements when not in use.
2Ease of manufacture
If a conventional connecting device with intermediate flange is used, then the attachment of the electric motor is simplified, but the radial loads and bending moments increase leading to early failure
Solution Approach 1:
The connecting device is merged with the actuator housing, eliminating the separate intermediate flange as an independent component. The housing itself is designed to directly receive and secure the electric motor, thereby reducing the number of connection points subjected to radial loads and bending moments while maintaining manufacturing simplicity.
Solution Approach 2:
The actuator housing serves multiple functions: it encloses the electromechanical components, provides structural support, and acts as the mounting structure for the electric motor. This multi-functionality eliminates the need for a separate intermediate flange while improving reliability by distributing loads throughout the housing structure.
3Ease of operation
If the electric motor is attached to the housing with intermediate flange, then the assembly is easier to construct, but the radial loads cause bending moments that increase the risk of early failure
Solution Approach 1:
The connecting device features are merged directly into the actuator housing structure, eliminating the intermediate flange. The housing is designed with integrated mounting surfaces and securing mechanisms that directly attach the electric motor, thereby maintaining assembly ease while eliminating the weak connection points that would experience damaging bending moments.
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 use of a spring pressure brake in the electromechanical actuator enhances the robustness and reliability of the middle buffer coupling by absorbing radial loads and reducing bending moments, thereby extending the lifespan of the connection and simplifying maintenance. This solution also standardizes components, saves costs by eliminating the intermediate flange, and improves the overall efficiency of the coupling process.
Implementation Method 1
The use of a spring pressure brake in the electromechanical actuator enhances the robustness and reliability of the middle buffer coupling by absorbing radial loads and reducing bending moments
Implementation Method 2
The connecting device comprises the motor brake as a spring-loaded brake
Data Source
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AI summary
A central buffer coupler (1) of a rail vehicle, comprising a housing (1a), a hook disc (2) with a pivot axis (2a), and an actuator (6) with an actuating element (7), wherein the actuating element (7) interacts with the hook disc, wherein the actuator (6) is designed as an electromechanical actuator (6) with at least one electric motor (10) and a motor brake (11), wherein the electric motor (10) of the electromechanical actuator (6) is connected to a housing (15) of the electromechanical actuator (6) by means of a connecting device (100), the connecting device (100) having a connecting flange (15a). The connecting device (100) includes the motor brake as a spring-applied brake (24). A rail vehicle with such a central buffer coupler (1) is provided.