Rail Vehicle Levelling Piston Guide for Controlled End-Stop Motion
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Solution Overview
Problem
Existing levelling systems for rail vehicles are not space-efficient and require complex assembly and maintenance, with limited control over relative movement between components, leading to potential issues with undesired forces like shear forces.
Innovation Solution
A levelling system comprising a levelling cylinder and piston with a guiding element that protrudes into a recessed groove within the cylinder, limiting relative movement and providing a form-fit mechanism for specific directional movement, thereby enhancing stability and simplifying assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional levelling systems use separate components for cylinder and piston with minimal guidance, then assembly and maintenance are complex, but the structure occupies more space and allows undesired relative movements
Solution Approach 1:
The guiding element is integrated directly into the piston structure, merging the guidance function with the piston component itself. This eliminates the need for separate guidance components, simplifying assembly and maintenance while reducing overall space occupation in the levelling system.
Solution Approach 2:
The piston is designed to serve multiple functions: it provides hydraulic action for levelling and simultaneously serves as a guidance element through its geometric shape. This multi-functionality reduces the number of separate components needed, thereby simplifying assembly and maintenance procedures.
2Ease of manufacture
If the levelling system allows free relative movement between piston and cylinder, then assembly is simpler, but undesired forces like shear forces cannot be effectively handled
Solution Approach 1:
The piston features an asymmetric geometric shape with a broader section that fits into a corresponding recess in the cylinder. This asymmetric design provides form-fit guidance that controls relative movement in specific directions while allowing necessary axial movement, effectively handling shear forces without complicating assembly.
3Reliability
If guiding elements protrude significantly from the piston, then control over relative movement is improved, but the assembly becomes more complex and space-consuming
Solution Approach 1:
The guiding element is formed as an integrated geometric feature of the piston itself rather than as a separate component. This composite approach combines the piston and guidance function into a single piece, providing reliable control over relative movement while eliminating the complexity of assembling separate guiding components.
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 integrated construction of the levelling system allows for efficient space utilization, simplified assembly, and effective handling of forces, providing a robust and maintainable solution with controlled movement and protection against undesired forces.
Implementation Method 1
the at least one recess of the levelling cylinder is formed as a groove extending on an inner diameter of the levelling cylinder and along a part of the longitudinal extension of the levelling cylinder, wherein the levelling piston comprises a central hole which is formed such that the at least one guiding element is able to be passed through
Data Source
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AI summary
The present invention relates to a levelling system (10; 10') for a vehicle, in particular a rail vehicle (12), comprising at least one levelling cylinder (18) and a levelling piston (16; 16'). The levelling piston (16; 16') is at least partially provided in the levelling cylinder (18) in a movable manner for setting the level of the rail vehicle (12). Further, the levelling system (10; 10') comprises at least one guiding element (20), which is arranged within the levelling piston (16; 16') and partially protrudes from the levelling piston (16; 16') into at least one recess (18b) of the levelling cylinder (18) such that an end stop in a longitudinal direction is provided for the relative movement between the levelling piston (16; 16') and the levelling cylinder (18).