Railcar Flange Assembly Transport Frame
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Solution Overview
Problem
The increasing size of wind turbine components, particularly flange assemblies, exceeds freight cargo dimensions and profiles, necessitating a compact, reliable, and cost-effective transportation method via railroad and other intermodal carriers.
Innovation Solution
A system utilizing a structural frame with inclines and dunnage in a railcar to support and secure oversized flange assemblies, preventing direct contact with the railcar and maintaining the load against tipping forces, which includes a movable stop for positioning and binding flanges together as a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flange assemblies are transported separately from tower sections using conventional methods, then shipping flexibility and cost are improved, but the flange assemblies exceed allowable freight cargo dimensions and cannot be accommodated by standard railcars
Solution Approach 1:
The flange assemblies are nested within a structural frame that is itself positioned within the railcar. The frame acts as an intermediary container, allowing the oversized flanges to be accommodated within standard railcar dimensions by hierarchically organizing the load structure.
Solution Approach 2:
The structural frame utilizes three-dimensional space optimization by positioning inclines and support structures at various angles and heights within the railcar. This allows the flange assemblies to be arranged in a compact configuration that fits within railroad clearance profiles while maximizing the use of available vertical and lateral space.
2Adaptability or versatility
If a structural frame is designed to accommodate oversized flange assemblies within standard railcars, then transportation of large components is enabled, but the device complexity increases
Solution Approach 1:
The structural frame is designed with multiple functions: it provides structural support for the flange assemblies, defines the load boundaries, interfaces with the railcar through standardized engagement means, and incorporates safety features. This multi-functionality reduces the need for separate components and simplifies the overall system despite accommodating oversized loads.
Solution Approach 2:
The structural frame is divided into distinct functional segments: engagement means for railcar attachment, inclines for load positioning, dunnage for support, and stops for securing. This segmentation allows each component to be optimized independently and simplifies assembly and disassembly operations.
3Reliability
If incline dunnage is used to support the load and prevent direct contact with the railcar, then load protection and stability are improved, but the device complexity increases
Solution Approach 1:
The incline dunnage acts as an intermediary element between the flange assemblies and the structural frame. It provides a stable, protected surface for the load while distributing forces and preventing direct contact that could cause damage. This simple intermediary component achieves load protection without requiring complex mechanisms.
4Reliability
If a movable stop is incorporated to maintain the load against tipping forces, then transportation safety is improved, but the device complexity increases
Solution Approach 1:
The stop is designed as a movable rather than fixed component, allowing it to be positioned and secured as needed during loading operations. This dynamic feature provides safety against tipping forces only when required, while maintaining simplicity by allowing the stop to be repositioned or removed if not needed for particular load configurations.
Data Source
AI summary
A system for transporting a load of plural flange assemblies using a railcar that has open top over a load-area. The system includes a structural frame configured for positioning at least partially about the load area of the railcar. The structural frame includes a first and second incline that are opposingly oriented to define a load trough, which is accessible for insertion of at least a portion of the load thereinto from above the open top of the railcar. A railcar engagement member is disposed to fixedly couple the structural frame to the railcar. Incline dunnage is positioned on the first and second incline so as to engage and support the load, and so as to prevent direct contact between the load and the railcar. A first movable stop is coupled to the structural frame, and has an adjustment for selectively positioning it to engage and maintain the load against tipping forces.