Modular Rail Vehicle Coupling System with Segmented Contact Carrier
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Solution Overview
Problem
Conventional coupling systems for rail vehicles require lengthy design and production processes due to complex mechanical and electrical coordination, leading to high costs and long delivery times, as each system must be custom-designed and manufactured to meet specific customer requirements.
Innovation Solution
A modular coupling system with separate contact carrier inserts, each equipped with contacts of the same function, allowing for standardized assembly and easy modification, reducing design and manufacturing efforts while maintaining flexibility and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a custom-designed contact carrier structure with multiple different contacts is used to meet specific customer requirements, then the coupling system achieves high adaptability and functionality, but the design and manufacturing complexity increases significantly
Solution Approach 1:
The contact carrier structure is divided into multiple separate contact carrier inserts, each carrying only contacts of the same function. This segmentation allows each insert to be designed and manufactured independently with simpler processes, while the overall system maintains full customization capability by selecting and combining different inserts.
Solution Approach 2:
The invention creates a universal contact carrier structure that can accommodate multiple functional types (digital data transmission, high-frequency signal transmission, low-frequency signal transmission, energy transmission) through a standardized interface. This allows a single base structure to serve multiple functions by simply changing the insert configuration.
2Adaptability or versatility
If a custom-designed contact carrier structure is manufactured for each project, then the coupling system meets specific customer requirements, but the delivery time increases due to lengthy design and production processes
Solution Approach 1:
By segmenting the contact carrier structure into standardized inserts, the invention enables parallel manufacturing of different insert types. This reduces the total production time compared to manufacturing a completely custom one-piece structure, as components can be produced simultaneously and then assembled.
Solution Approach 2:
The contact carrier inserts are pre-designed and pre-manufactured as standardized components before the final coupling system is assembled. This preliminary preparation of modular components significantly reduces the overall delivery time compared to traditional custom manufacturing processes.
3Adaptability or versatility
If a one-piece contact carrier structure with multiple different contacts is used, then the coupling system achieves complete functionality, but the manufacturing precision requirements increase due to complex coordination
Solution Approach 1:
The contact carrier structure is segmented into separate inserts, each containing contacts of the same function. This eliminates the need for complex coordination between different contact types during manufacturing, as each insert can be manufactured independently with standard precision requirements. The modular interface provides standardized alignment features.
Solution Approach 2:
Each contact carrier insert is optimized for its specific function with localized quality control. For example, gold-plated contacts for high-frequency signal transmission can be manufactured with specific plating thickness tolerances, while silver-plated low-frequency contacts have different specifications. This local optimization is easier to achieve than uniform high-precision manufacturing across all contacts.
Data Source
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AI summary
The invention relates to a coupling system (29) for a rail vehicle, comprising a coupling (30) having a coupling housing (32), a contact carrier structure (34) attached to the coupling housing (32) and a plurality of contacts (54a, 54b, 56a, 56b, 58a, 58b, 60a, 60b), which are mounted on the contact carrier structure (34) and which each have one of a plurality of different functions. The contact carrier structure (34) can be assembled from multiple separate contact carrier inserts (44a, 44b, 46a, 46b, 48a, 48b, 50a, 50b). From the plurality of contacts (54a, 54b, 56a, 56b, 58a, 58b, 60a, 60b), only those that have the same function are mounted on each of the separate contact carrier inserts (44a, 44b, 46a, 46b, 48a, 48b, 50a, 50b).