Rail Brake Shoe Backplate Structure for Higher Flexural Rigidity
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Solution Overview
Problem
Existing brake pads for rail wheel brakes face challenges in maintaining stability and optimal attachment due to impaired flexural rigidity from perforations and limited contact area, leading to suboptimal performance under high mechanical loads and increased production costs.
Innovation Solution
The brake pad features cup-shaped shaped elements produced by forming, which act as both rivets and anti-rotation features, maintaining the back plate's surface integrity and providing a larger adhesive surface, along with positioning bolts for enhanced stability and secure attachment, allowing for uninterrupted material flow and improved load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the back plate is perforated to attach the support grid, then the support grid can be connected to the brake block, but the flexural rigidity of the back plate is impaired
Solution Approach 1:
The back plate is segmented into multiple regions: solid edge areas that maintain flexural rigidity and load-bearing capacity, and perforated central areas that provide attachment points for the support grid. This segmentation allows the plate to simultaneously achieve structural strength and ease of attachment.
Solution Approach 2:
Different regions of the back plate have different qualities: the edge regions maintain solid material structure for high flexural rigidity, while the central regions are perforated for attachment functionality. This local differentiation resolves the contradiction between strength and ease of manufacture.
2Strength
If the back plate thickness is increased to improve stability under high mechanical loads, then the flexural strength is improved, but the procurement and production costs increase
Solution Approach 1:
Instead of uniformly increasing the thickness of the entire back plate, the invention segments the plate into solid edge regions (providing strength) and perforated central regions (reducing material usage). This allows achieving the required flexural strength without the cost penalty of increasing overall plate thickness.
Solution Approach 2:
The invention changes the structural parameters of the back plate by introducing a specific perforation pattern and solid edge region configuration, rather than simply changing the thickness parameter. This parameter change achieves improved strength-to-cost ratio.
3Ease of manufacture
If the support grid has edge recesses at the openings in the back plate, then the support grid can be attached to the back plate, but the contact area for connection is reduced
Solution Approach 1:
The support grid attachment system is segmented into multiple discrete attachment points distributed across the back plate, rather than relying on a single large contact area. This segmentation allows adequate connection strength while maintaining sufficient total contact area.
Solution Approach 2:
The attachment system transitions from a two-dimensional contact area problem to a three-dimensional solution by using rivet pins that extend through the back plate and support grid, creating attachment strength in the thickness dimension rather than relying solely on surface contact area.
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 solution enhances the brake pad's flexural rigidity and service life by maintaining the back plate's integrity, ensuring even wear and improved braking performance, significantly reducing the need for frequent replacements and associated costs.
Implementation Method 1
the shaped elements are now produced exclusively by forming or cold forming
Implementation Method 2
which are deformed in this way after the support grid has been placed so that a positive connection between the support grid and the back plate is produced
Implementation Method 3
the brake block is pressed onto the running surface of the rail wheel to generate a frictional force
Data Source
Figure 1
Figure 2~3
AI summary
Disclosed is a brake shoe for a rail vehicle wheel brake, comprising a lining support (2) that supports a brake shoe rubbing surface (3) and includes a sheet metal backplate (4) and a supporting grating (7) which is connected to the backplate (4) and to which the brake shoe rubbing surface (3) is joined. The backplate (4) is provided with shaped elements (5) on the side facing away from the supporting grating (7) in order for the backplate (4) to rest in a twist-proof manner on a brake shoe holder, and is provided with shaped elements (6) on the side facing the supporting grating (7) in order for the backplate (4) to interlock with the supporting grating (7) . The disclosed brake shoe is designed in such a way that the shaped elements (5, 6) provided on both sides of the backplate (4) have the shape of cups obtained by a deep drawing process.