Rail Vehicle Air Spring Feed via Extruded Profile Bore
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Solution Overview
Problem
Existing air suspension systems in rail vehicles face challenges in maintaining and repairing the compressed air supply due to inaccessible connection points between the air spring and the main cross member, leading to high maintenance costs and reduced durability of flexible air ducts.
Innovation Solution
An air supply system for rail vehicles featuring a main cross member with a closed profile chamber of circular cross-section, connected to the air spring via a bore, allowing for easy access and maintenance, and utilizing a connecting piece with a transverse bore for air flow, eliminating the need for internal threads and complex sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed compressed air connection is made through the main crossbeam, then the air supply reliability is improved, but the maintenance accessibility deteriorates
Solution Approach 1:
The air supply system is segmented into modular components: the air spring, the connection piece with external threading, and the sealing elements. This segmentation allows the connection piece to be accessed and maintained separately from the main crossbeam structure, resolving the contradiction between reliable fixed connection and maintainable accessibility.
Solution Approach 2:
A connection piece acts as an intermediary element between the air spring and the compressed air line. This intermediary component features external threading that allows it to be screwed into the main crossbeam from the accessible side, while maintaining a sealed internal connection to the air spring. This mediator enables both reliable fixed connection and easy maintenance access.
2Ease of repair
If a flexible compressed air line is used for easier access, then the maintenance accessibility is improved, but the system durability deteriorates
Solution Approach 1:
The connection piece incorporates dynamic sealing elements (O-rings, packing rings) that maintain sealing effectiveness while accommodating minor movements and thermal expansions. This dynamic sealing approach provides the flexibility needed for maintenance access while maintaining the durability of the overall rigid air supply system.
3Reliability
If internal threads are produced in the main crossbeam for connection, then the connection reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
Instead of producing internal threads inside the main crossbeam (which would be difficult and complex), the threading is inverted and placed on the external surface of the connection piece. This inversion allows standard threading operations to be performed on the connection piece during manufacturing, while the main crossbeam requires only a simple tapped hole or recess, significantly reducing manufacturing complexity while maintaining connection reliability.
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 design simplifies maintenance, reduces costs, and enhances durability by keeping all sealing points accessible, avoiding the need for internal welding and thread production, while ensuring the air spring's spring behavior is not compromised.
Implementation Method 1
The air pressure system of the air spring is equipped with means for inflation and deflation
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an air feed for an air spring (3) of a rail vehicle, comprising a main crossbeam (1) composed of at least one extruded light-metal profiled element (2), which light-metal profiled element is oriented in the longitudinal direction of the rail vehicle in the installed position of the main crossbeam (1), and an air spring (3), which is arranged on the main crossbeam (1), wherein the main crossbeam (1) comprises at least one closed profile chamber (4) having a circular cross-section, which profile chamber extends over a certain length of the extruded light-metal profiled element (2), and wherein at least one borehole (5) in a wall of the main crossbeam (1) connects the gas chamber (6) of the air spring to the profile chamber (4).