Rail Vehicle Generator Coupling With Segmented Flanges
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Solution Overview
Problem
Existing wheel axle generator couplings in rail vehicles are prone to damage from shocks and frictional heat due to rigid drive trains, leading to high maintenance and repair costs, as well as downtime when the damping elements wear out or break.
Innovation Solution
A wheel axle generator coupling design featuring a rotatable inner flange and separate inner and outer flanges with breaking elements allows independent rotation of the cardan and generator shafts, preventing frictional heat and enabling easy replacement of breaking elements without disassembly, thus reducing material and transport costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a rigid drivetrain is used to transmit power from the wheel axle to the generator, then power transmission efficiency is improved, but the system becomes vulnerable to shock damage and frictional heat when the generator locks up
Solution Approach 1:
The coupling is divided into separate inner and outer flanges connected by breaking elements, allowing the system to segment and disconnect when needed. The inner flange can rotate independently relative to the outer flange when breaking elements fail, creating functional segments that prevent damage propagation.
Solution Approach 2:
The breaking elements are designed with a predetermined breaking point to fail beforehand under excessive load, preventing the transmission of harmful shock forces and frictional heat to the generator. This sacrificial component cushions the system against damage before it occurs.
2Object-affected harmful factors
If damping elements with projections are used to cushion shocks, then shock protection is improved, but the coupling requires complete disassembly and replacement when the damping element wears out or breaks
Solution Approach 1:
The breaking elements are separate, replaceable components positioned radially between the flanges, allowing individual replacement without removing the entire coupling assembly. This segments the repair task into a simple component swap rather than complete disassembly.
Solution Approach 2:
The radial positioning of breaking elements allows them to be replaced from the outside of the coupling without disassembly, enabling on-site maintenance and eliminating the need for workshop repairs. The design facilitates self-service replacement by the operating crew.
3Strength
If the inner flange is fixed to the outer flange, then structural integrity is improved, but the system cannot accommodate generator lockup without transmitting damaging forces
Solution Approach 1:
The breaking elements are pre-positioned between the inner and outer flanges in a load-bearing configuration. Under normal operation, they maintain structural integrity and transmit power. When excessive force occurs, they fail in advance to prevent damage, having already performed their protective function.
Solution Approach 2:
The breaking elements are designed as inexpensive, replaceable sacrificial components with a predetermined breaking point. They are meant to fail under excessive load to protect more valuable components, and can be quickly replaced without removing the entire coupling.
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 allows for quick and cost-effective restoration of the coupling, avoiding damage to the rail vehicle and track, enabling on-site repairs and minimizing downtime.
Implementation Method 1
a rubber-elastic damping element (26) arranged between the drive flange (22) and the output flange (24)
Implementation Method 2
which cushions the shocks
Implementation Method 3
a breaking element (38) connectable in a form-fitting manner to the outer flange (30) and the inner flange (28)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a wheel axle generator coupling for connecting a cardan shaft (16) operatively connected to an axle (12) of the rail vehicle (10) to a generator shaft of a current generator (20) held on the rail vehicle (10), to a drive flange (22) connectable to the cardan shaft (16) and to an output flange (24) connectable to the generator shaft, wherein a rubber-elastic damping element (26) is provided between the drive flange (22) and the output flange (24).Creating a wheel axle-generator coupling that can be quickly, easily and with minimal material expenditure is achieved by the output flange (24) comprising an inner flange (28) connectable to the generator shaft and, separate from the inner flange (28), an outer flange (30) engaging the damping element (26), wherein the inner flange (28) is connected to the outer flange (30) by at least one breaking element (38), in particular by a positive locking connection.