Modular Rail Vehicle Joint with Interchangeable Adapter Plates
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Solution Overview
Problem
The existing production methods for rail vehicle joints require separate joints for each vehicle type, leading to high costs due to expensive X-ray inspections for cracks and cavities in cast joints, which are not suitable for multiple series use.
Innovation Solution
A modular system where a single prefabricated joint is used with interchangeable adapters of varying shapes and sizes to accommodate different vehicle widths, featuring detachable attachment via screws or welding, and incorporating pins for force transmission to avoid shear stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate cast joints are constructed for each vehicle type, then the joint can be specifically adapted to each vehicle's requirements, but the production cost increases significantly due to expensive X-ray inspections for each individual joint
Solution Approach 1:
The joint system is divided into two segments: a universal joint body that remains the same across all vehicle types, and vehicle-specific adapter components that are attached to the joint body. This segmentation allows the expensive joint inspection process to be performed only once on the universal joint body, while adapters can be manufactured separately and attached as needed for different vehicle configurations.
Solution Approach 2:
A single universal joint body is designed to serve multiple vehicle types through the use of interchangeable adapters. The joint body possesses universal mounting interfaces and force transmission capabilities that can accommodate various adapter configurations, enabling one joint design to fulfill multiple specialized functions across different rail vehicle series.
2Length of moving object
If the joint is designed with different lengths for different vehicle widths, then the minimum distance between vehicle parts can be maintained, but the device complexity increases due to multiple joint variants
Solution Approach 1:
The joint system is divided into a standardized joint body and variable-length adapter components. The adapter serves as the segmented element that provides different lengths and configurations to accommodate various vehicle widths, while the joint body remains standardized. This reduces design complexity by concentrating the variability in the adapter rather than the entire joint assembly.
Solution Approach 2:
The adapter acts as an intermediary component between the universal joint body and the vehicle-specific mounting points. It mediates the difference between the standardized joint interface and the varied vehicle width requirements, providing the necessary length adjustments and geometric adaptations without modifying the joint body itself.
3Ease of operation
If screws are used to attach the adapter to the joint, then the adapter can be detachably fastened, but the screws are subjected to shear stresses from rolling, pitching and buckling movements
Solution Approach 1:
The shear stress-bearing function is extracted from the screw connection and assigned to a dedicated pin element. The screw's role is reduced to providing detachable fastening and clamping force, while the pin specifically handles the shear stresses generated by rolling, pitching, and buckling movements. This separation of functions allows each component to be optimized for its specific role.
Solution Approach 2:
The connection system incorporates a pin that can accommodate dynamic shear stresses from vehicle movements. The pin is designed to flex and absorb the varying shear loads during operation, while the screw maintains a constant clamping force. This dynamic design allows the detachable connection to remain strong under operational loads while preserving ease of assembly and disassembly.
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 approach reduces production costs and simplifies inspections by allowing a single joint to be adapted for various vehicle sizes, effectively managing movement forces while minimizing stress on attachment points.
Implementation Method 1
the pin sits in the respective opening with a press fit
Data Source
Figure 1~2
Figure 3
AI summary
The vehicle has a joint arranged between two vehicle parts (1, 2) and connected with the vehicle parts by an adapter (20). The adapter is inserted between the joint and one of the vehicle parts. An adapter plate is attached to two ends of the adapter for attachment at the joint or the vehicle parts, where the joint includes front plates (11, 12). The front plates and the adapter plate have a respective identical hole pattern for retaining screws. The adapter is screwed or welded onto the vehicle parts and formed in a trapezoidal shape.