Hull-Plug Energy Dissipating Device for Train Couplers
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Solution Overview
Problem
Existing energy dissipating devices in multi-car vehicle connection systems are heavy, difficult to manufacture, and challenging to repair after a crash, as they often require deformation of the entire cross-section of deformation tubes, which complicates assembly and post-crash maintenance.
Innovation Solution
The introduction of a hull surrounding the plug of the connection device, which deforms when a force above a certain threshold is applied, allowing for energy dissipation without cutting into material, and can be easily assembled and replaced, incorporating gas hydraulic dampers for additional energy dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If deformation tubes are used to dissipate energy by deforming the entire cross-section, then energy dissipation capability is improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The energy dissipating device is divided into separate modular components: a plug (containing the rod and hull) that can be independently replaced from the mandrel and connection device body. This segmentation allows the heavy deformation tube to be replaced with a lighter hull that deforms in a different manner, reducing overall weight while maintaining energy dissipation functionality.
Solution Approach 2:
The hull is designed as a disposable or easily replaceable component that deforms during a crash to dissipate energy. After a collision event, the deformed hull can be quickly replaced without replacing the entire energy dissipating device or connection device, reducing maintenance costs and weight compared to traditional deformation tubes that require full cross-section deformation.
2Loss of energy
If deformation tubes are used to dissipate energy by deforming the entire cross-section, then energy dissipation capability is improved, but ease of manufacture deteriorates
Solution Approach 1:
By segmenting the energy dissipating device into a plug (with hull and rod) and a mandrel, the manufacturing process is simplified. The hull can be manufactured separately as a simpler component compared to traditional deformation tubes, and assembled into the plug before installation into the connection device, improving ease of manufacture.
Solution Approach 2:
Instead of deforming the entire cross-section of a tube as in traditional designs, this invention inverts the approach by having the hull deform while surrounding a rigid rod. The rod maintains structural integrity while the hull absorbs energy through deformation, simplifying the manufacturing requirements for each component.
3Loss of energy
If deformation tubes are used to dissipate energy by deforming the entire cross-section, then energy dissipation capability is improved, but ease of repair deteriorates
Solution Approach 1:
The plug containing the deformed hull can be independently removed and replaced from the mandrel and connection device body after a crash. This segmentation enables quick repair by simply replacing the plug assembly rather than disassembling the entire connection device or replacing a complex deformation tube, significantly improving ease of repair.
Solution Approach 2:
The hull is designed as a disposable component that deforms during a crash and can be quickly replaced. The plug assembly (rod + hull) can be replaced as a unit without complex disassembly, making post-crash repair simple and fast compared to traditional deformation tube systems.
4Ease of manufacture
If a hull surrounding the plug is introduced for energy dissipation, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The rod and hull are combined into a single plug assembly that functions together for energy dissipation. The rod provides structural support while the hull deforms to absorb energy, merging two functions into one integrated component that simplifies the overall device architecture despite adding a hull element.
Solution Approach 2:
The plug assembly with hull serves multiple functions: the rod provides structural support and force transmission, while the hull provides energy dissipation through deformation. This multi-functional design achieves energy dissipation without requiring separate complex mechanisms, balancing device complexity with manufacturing ease.
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
This solution results in a lighter, easier-to-manufacture, and more easily repairable energy dissipating device that can be added or replaced independently, providing enhanced energy dissipation capabilities while reducing the overall weight and complexity of the connection device.
Implementation Method 1
at least a part of the plug is deformed, when the plug is at least partially moved through the opening
Implementation Method 2
The maximum diameter of the hull in a plane perpendicular to the longitudinal axis is larger than the minimum diameter of the opening of the mandrel, wherein said hull is at least partially deformed for dissipating energy
Implementation Method 3
incorporating gas hydraulic dampers for additional energy dissipation
Implementation Method 4
incorporating gas hydraulic dampers for additional energy dissipation
Data Source
AI summary
The invention relates to an energy dissipating device suitable to be used as part of a connection device that connects a first car of a multi-car vehicle with a second car of the multi-car vehicle, comprising a plug that has a longitudinal axis and a mandrel that has an opening, whereby the plug is arranged to be moved at least partially through the opening, if a force pointing in the longitudinal axis is applied to the plug, and whereby at least a part of the plug—especially its hull—is deformed, when the plug is at least partially moved through the opening, whereby said hull being at least partially deformed, when the plug is at least partially moved through the opening. The hull is attached to the rod by clamping or fixing with fasteners, preferably with protrusions around the rod and/or at least one plug or nut. The hull is a relatively independent element which can be put over a rod and therefore the hull can be mounted or unmounted subsequently to a rod without influencing the stability or main function of the connection device.