Rail Vehicle Coupling Plug with Integrated Conductor Tracks
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Solution Overview
Problem
The existing electrical contact couplings for rail vehicles are complex and expensive to produce due to their redundant design, requiring precise centering and high mating cycle resistance, making them difficult to assemble and maintain.
Innovation Solution
A plug connection unit with a conductor track for electrical connection of redundant contacts, allowing for easier assembly and tolerance compensation using modular design with fixed and plug/socket elements, and incorporating a spiral spring for positional adjustment, along with optional heating and sensing components to ensure alignment and moisture protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If redundant contacts are arranged to the left and right of a central axis in a complementary manner, then the train can turn around, but the construction becomes very complex and expensive
Solution Approach 1:
The patent combines multiple redundant contacts and their cabling into a single integrated contact carrier. The contact carrier integrates both left and right redundant contacts with internal conductor tracks, eliminating the need for separate cabling between redundant contacts. This merging reduces construction complexity while preserving the redundant complementary contact arrangement needed for turning around.
Solution Approach 2:
The contact carrier acts as an intermediary component that houses and connects multiple contacts internally. Instead of directly connecting redundant contacts with external cables, the contact carrier provides an internal connection structure (conductor tracks) that simplifies the overall construction while maintaining the redundant contact functionality.
2Manufacturing precision
If precise centering devices are used to guide e-coupling heads, then contacts meet exactly, but the device complexity increases
Solution Approach 1:
The contact carrier integrates multiple contacts in a fixed geometric arrangement with built-in tolerance compensation features. By combining contacts and their alignment features into a single rigid structure, the patent reduces the need for complex external centering devices while maintaining precise contact alignment through the integrated design.
3Device complexity
If contacts are designed as single integrated units, then construction is simpler, but tolerance compensation becomes difficult
Solution Approach 1:
The patent incorporates elastic contact elements within the contact carrier that can deform to compensate for positional tolerances. These dynamic elements allow the contact carrier to adapt to manufacturing variations while maintaining reliable electrical contact, thus preserving construction simplicity without sacrificing tolerance compensation capability.
4Reliability
If cable connections are used between redundant contacts, then electrical connection is achieved, but the construction becomes more complex
Solution Approach 1:
The contact carrier integrates multiple contacts and their electrical connections into a single unit with internal conductor tracks. This merging eliminates the need for external cabling between redundant contacts, reducing construction complexity while maintaining reliable electrical connections through the integrated conductor track system.
Solution Approach 2:
The conductor tracks within the contact carrier serve as intermediaries that provide internal electrical connections between contacts. Instead of using external cables, the conductor tracks act as built-in connection pathways that simplify the overall construction while ensuring reliable electrical connectivity.
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
Simplifies the construction and maintenance of electrical contact couplings by eliminating cabling between redundant contacts, enhancing reliability and longevity through modular design and tolerance compensation, while ensuring precise alignment and moisture protection.
Implementation Method 1
The contact element can be an annular spiral spring which is inserted into the socket in such a way that the contacts are in contact via the spiral spring when the plug is inserted
Implementation Method 2
the carrier can include a heater. In this way it can be avoided that unwanted moisture is deposited in the plug connection. Furthermore, it can be ensured in this way that the thermal expansion is the same, so that plug connection units of the automatic electrical contact coupling that meet one another during coupling are exactly aligned with one another
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a connector unit (1) suitable for use in an electrical contact coupling (2) of a rail vehicle, in particular a train, for connecting a plurality of cables of two vehicle parts, for transmitting electrical impulses and/or power, comprising a carrier (5) and a plurality of contacts (3, 4) attached thereto, wherein at least one connection is redundant, the contacts (3, 4) of which are arranged to the left and right of a central axis (19) and are complementary. To reduce the wiring effort, it is proposed to provide at least one conductor track (11) on the carrier (5) by means of which the redundantly configured contacts (3, 4) are electrically connected.