Rail Car Power Connector Layout for Cable Pull Relief
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Solution Overview
Problem
Existing electrical connecting apparatuses for rail vehicles face difficulties in handling due to the weight and size of cables and plug connectors, requiring significant effort to establish a secure connection, often necessitating assistance and being prone to buckling loads that can cause the connectors to pull apart.
Innovation Solution
The apparatus features angled plug connectors where the cable outlet direction is opposite to the plugging direction, incorporating a holding device to secure the connectors and absorb pulling forces, allowing for easier and secure connection without manual locking, and a compact design with optional latching for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cable length is increased to ensure relative mobility of consecutive cars, then the cable can accommodate car movement, but the cable hangs downwards and creates pulling force on the plug connector
Solution Approach 1:
The cable outlet direction is changed from a vertical downward orientation to an angled orientation (e.g., 45 degrees or horizontally). This dimensional change in the cable routing direction redirects the gravitational pull and buckling forces away from the plug connector's plugging direction, allowing the cable to accommodate car movement while preventing excessive pulling forces on the connector.
2Strength
If the plug connector is plugged in along the cable outlet direction to counteract buckling load, then the connector can handle cable weight, but the pulling force can still cause connectors to be pulled apart
Solution Approach 1:
The plug connector's plugging direction is oriented at an angle (e.g., 45 degrees or horizontally) relative to the cable outlet direction rather than being aligned with it. This angular orientation creates a geometric configuration where the cable's vertical downward pull and buckling forces are resolved into components that do not directly oppose the plugging direction, thereby maintaining connection strength while improving reliability.
Solution Approach 2:
The plug connector design incorporates asymmetric orientation where the plugging direction is deliberately angled relative to the cable outlet direction. This asymmetric configuration optimizes the mechanical strength to resist buckling loads while preventing the cable's gravitational pull from causing the connectors to separate, thereby simultaneously achieving strength and reliability.
3Strength
If considerable effort is applied to hold and lock the plug connector during plugging, then the connection can be established, but it requires coordination that is difficult to achieve alone
Solution Approach 1:
By changing the plugging direction to be angled relative to the cable outlet direction, the connector geometry itself provides mechanical advantage. The angled orientation naturally resists the cable's pulling force through geometric configuration, reducing the manual holding effort required and simplifying the plugging operation to a single-handed task.
Solution Approach 2:
The plug connector's angled design allows it to self-support against the cable's buckling load and gravitational pull through its geometric configuration. The connector structure itself provides the necessary mechanical resistance, reducing or eliminating the need for additional locking mechanisms or multi-person coordination, thereby enabling easy single-handed operation.
4Device complexity
If multiple cables are combined in a common plug connector, then the power supply phases are integrated, but the connector becomes stiff and heavy making handling difficult
Solution Approach 1:
The plug connector is designed with an angled plugging direction relative to the cable outlet direction. This angular configuration optimizes the mechanical leverage and distribution of forces across the multiple integrated cables and contact elements, reducing the overall stiffness and weight perception during handling while maintaining the integration of all power supply phases.
Data Source
AI summary
Disclosed is an electrical connecting apparatus for supplying power to cars which are coupled to one another, including a first plug-in connector to which at least one cable is connected, and a corresponding second plug-in connector which is intended to be fastened to a car wall, in particular in a vertical lateral wall. The first plug-in connector and the second plug-in connector are each provided with one or more corresponding first contact elements or second contact elements which can be plug-connected in an insertion direction (A), and the cable of the first plug-in connector exits from the first plug-in connector in a first cable outlet direction (B) which is angled away in relation to the insertion direction (A). Also disclosed is a rail vehicle having at least two coupled cars, wherein each of the two coupled cars is provided with at least one electrical connecting apparatus as above described.