Rail Vehicle Frame Using Riveted Connectors for Weld-Free Assembly
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Solution Overview
Problem
The existing frameworks for electrical equipment in rail vehicles are heavy and require complex welding processes, which increase production effort and weight, and lack efficient attachment methods to load-bearing parts, compromising stability and durability.
Innovation Solution
A framework design using elongated profile elements connected via riveted connecting elements, eliminating the need for welding and providing stable corners with low production effort, allowing for lightweight and stable attachment to load-bearing parts without welding, using galvanized steel profile elements and electroplated components for corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect profile elements, then connection stability is improved, but production complexity and effort increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using connecting elements that have hooks engaging with profile elements. This substitution eliminates the complexity of welding operations, special training requirements, and post-welding corrosion protection while maintaining connection stability through the mechanical interlocking mechanism.
2Reliability
If additional strengthening elements are added to framework corners, then corner stability is improved, but framework weight increases
Solution Approach 1:
The connecting elements serve multiple functions simultaneously: they connect profile elements to each other at corners, provide strengthening at corner joints, and offer attachment points for fastening to load-bearing parts of the rail vehicle. This multi-functionality eliminates the need for separate strengthening elements, reducing overall framework weight while maintaining corner stability.
Solution Approach 2:
The patent merges the functions of corner connection, corner strengthening, and attachment to load-bearing parts into a single integrated connecting element. This combining of functions eliminates redundant components and reduces the overall weight of the framework while ensuring corner stability and proper attachment.
3Adaptability or versatility
If eyelets or recesses are added for attachment, then attachment capability is improved, but production effort and weight increase
Solution Approach 1:
The connecting elements are designed with integrated fastening elements that provide attachment capability directly as part of the connection mechanism. This eliminates the need for separate eyelets or recesses, reducing production effort while maintaining attachment versatility to load-bearing parts of the rail vehicle.
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 solution achieves a lightweight, stable, and vibration-damping framework with reduced production effort, ensuring secure attachment to rail vehicle components without the need for welding, enhancing durability and ease of assembly.
Implementation Method 1
using galvanized steel profile elements and electroplated components for corrosion protection
Implementation Method 2
achieves a lightweight, stable, and vibration-damping framework
Data Source
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AI summary
The frame has a first set of profile elements (4, 5), a second set of profile elements (6, 9) and a third set of profile elements (7, 8) connected together on corners of the frame via a first set of connectors (1, 2) and a second connector (3). The second connector is connected with the second and third set of profile elements and with the first set of connectors. The first set of connectors and/or second connector is designed as a fastening element for fastening the frame with an object at parts of a rail vehicle. An independent claim is also included for a method for manufacturing a frame.