Grating with Inconsistent Hole Pattern for Attachment
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Solution Overview
Problem
The existing running board assemblies for railway freight cars require manual measurement for attaching grab irons, which introduces the possibility of assembly errors due to the need for precise hole alignment, complicating the installation process.
Innovation Solution
A grating design featuring a repeated pattern of uniform surface modifications with strategically placed areas of inconsistency that serve as indicators for attaching structures, eliminating the need for precise measurement by providing a clear attachment point, and potentially incorporating different sized fastener holes within these areas for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual measurement is used to locate holes for attaching grab irons, then flexibility in attachment location is maintained, but assembly errors occur and installation complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-defining the attachment location through an inconsistency in the hole pattern during the manufacturing process. The running board is produced with a specific hole configuration where the absence or different arrangement of holes at predetermined locations indicates exactly where to attach grab irons, eliminating the need for measurement and location decisions during installation.
Solution Approach 2:
The hole pattern serves as an intermediary that communicates attachment location information from the design phase to the installation phase. The inconsistent hole arrangement acts as a visual guide or mediator that translates complex measurement requirements into simple visual cues for the installer.
2Strength
If precise hole alignment is required for attaching grab irons, then attachment strength is improved, but the installation process becomes more complex and time-consuming
Solution Approach 1:
The manufacturing process performs the alignment function in advance by creating a non-uniform hole pattern that inherently marks the correct attachment locations. This preliminary action ensures that when installers see the hole pattern, the precise alignment points are already identified, eliminating time-consuming measurement and alignment procedures during installation.
3Ease of manufacture
If a standardized hole pattern is used across the running board, then manufacturing simplicity is maintained, but attachment location identification becomes difficult
Solution Approach 1:
The patent applies local quality by maintaining a standardized uniform hole pattern for most of the running board surface while introducing localized inconsistencies at specific attachment points. The majority of the board uses simple, regular spacing for ease of manufacture, but specific areas have modified hole arrangements that provide attachment location information, combining manufacturing simplicity with functional information.
Solution Approach 2:
The inconsistency in the hole pattern introduces asymmetry at attachment locations while maintaining overall symmetry in the manufacturing process. The non-uniform distribution of holes at specific points creates visual indicators that break the pattern, providing necessary information without requiring complex manufacturing procedures.
Data Source
AI summary
A grating for a support structure includes a piece of metal including a perimeter edge and a surface bound by the perimeter edge. The piece of metal defines an array of uniform surface modifications on the surface of the piece of metal. The uniform surface modifications are arranged in a repeated pattern across the surface. The repeated pattern of uniform surface modifications is consistent across the surface but for at least a pair of spaced apart areas of inconsistency where the uniform surface modifications are not formed in the surface. Each area of inconsistency is surrounded on all sides by the array of uniform surface modifications. The pair of areas of inconsistency provides an indication of where to attach a structure to the grating.