Modular Railcar Mover Drive Train with Independent Wheel Control
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Solution Overview
Problem
Conventional railcar movers with rigid axles suffer from traction issues due to the inability to independently control the speed and torque of each rail wheel, leading to energy loss during turns, as the inside and outside rail wheels must maintain the same speed, causing mechanical constraints and inefficiencies.
Innovation Solution
A modular drive train system with independently controlled electric drive motors and gearboxes for each rail wheel, allowing for differential power supply to each wheel, enabling precise speed control and reducing mechanical connections, thereby improving traction and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid axles with differential locking feature are used, then mechanical strength and structural simplicity are improved, but traction performance and energy efficiency deteriorate due to inability to vary speed and torque to each rail wheel
Solution Approach 1:
The patent divides the drive train into independent modular units, with each rail wheel having its own electric drive motor and gearbox. This segmentation allows each wheel to be controlled independently, eliminating the energy loss associated with rigid axles while maintaining structural integrity through modular design.
Solution Approach 2:
The patent replaces the mechanical rigid axle system with an electrically-controlled modular drive train. Each rail wheel is driven by its own electric motor, substituting the mechanical differential locking system with electronic control, thereby eliminating traction losses while maintaining the necessary mechanical strength.
2Device complexity
If locked axles are used, then structural simplicity is improved, but turning performance deteriorates due to inability to accommodate different turning radii of inside and outside rail wheels
Solution Approach 1:
The patent implements a dynamic control system where the speed and torque of each electric drive motor can be independently adjusted based on turning requirements. During turns, the system dynamically varies the speed of inside and outside rail wheels to match their different turning radii, improving turning performance while maintaining operational simplicity through automated control.
Solution Approach 2:
The patent changes the operational parameters of each drive unit independently, allowing speed and torque to vary per wheel based on operational conditions. This enables optimal turning performance by adjusting parameters for inside and outside wheels differently, while the control system maintains simplicity through automated parameter management.
3Power
If conventional drive train with multiple mechanical connections is used, then power transmission is improved, but system efficiency deteriorates due to gearing losses in transmission
Solution Approach 1:
The patent segments the power transmission system into independent electric drive units, eliminating the need for complex mechanical linkages and gear transmissions between wheels. Each electric motor directly drives its associated gearbox and rail wheel, reducing the number of mechanical connections and minimizing gearing losses while maintaining effective power transmission.
Solution Approach 2:
The patent replaces the mechanical power transmission system with an electrical distribution system. Power is transmitted electrically to independent electric motors at each wheel station, eliminating the mechanical gear transmissions and associated losses, thereby improving system efficiency while maintaining adequate power delivery to each wheel.
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 system enhances traction and efficiency by allowing individual control of each rail wheel's speed and torque, reducing energy losses and enabling smoother turns and better handling of varying track conditions.
Implementation Method 1
A first electric drive motor may be connected to a first gearbox that is also connected to a first rail wheel... a second electric drive motor connected to a second gearbox that is connected to a second rail wheel
Data Source
AI summary
A modular drive train assembly is disclosed for the rail wheels of a railcar mover that provides a plurality of electric drive motors. Each electric drive motor may be connected to a gearbox and subsequently connected to a rail wheel. An automated control system may further control the power supplied to each of the electric drive motors such that the power supplied to each electric drive motor may be individually controlled to enhance the traction of each rail wheel. In addition, a plurality of sensors may monitor and communicate information from the electric drive motors to allow the control system to automatically control the power to each of the electric drive motors to enhance traction of the railcar mover.