Railcar Floor Structure with Intermediary Receiving Members

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Solution Overview

Problem

Conventional railcar floor structures lack strength, leading to increased complexity and cost due to the need for multiple molds for underfloor device arrangements, and inadequate support for passenger loads from corrugated plates.

Innovation Solution

A railcar floor structure featuring a pair of side sills, cross beams, and receiving members with leg portions that extend from the floor plate contact portion to the bottom surface of the supporting member, providing adequate stiffness and load support with a simple configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a conventional sub-floor structure with floor pan is used, then the floor can be formed by press forming or roll forming, but the strength of the railcar is not improved and multiple molds are required increasing cost

Engineering Contradiction:

Improvefloor formation methodVSAvoidrailcar strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The floor structure is divided into multiple functional components: supporting members with convex portions for structural strength, receiving members for load support, and floor panels for the finished surface. This segmentation allows each component to be optimized independently - the supporting members provide stiffness while the floor panels can be formed using conventional methods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The supporting members extend in the railcar longitudinal direction with convex portions in the width direction, creating a three-dimensional structure that provides strength in multiple directions. This dimensional approach allows the floor structure to resist torsional deformation while maintaining ease of manufacture through standardized components.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If the arrangement pitch of cross beams is changed due to underfloor devices, then the floor structure can accommodate devices, but a plurality of molds are required increasing cost

Engineering Contradiction:

Improvedevice arrangement flexibilityVSAvoidmold cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The receiving members are designed with a universal structure that can accommodate various underfloor devices at different positions. The standardized receiving member design with leg portions allows it to function both as a floor support and as a mounting structure for devices, eliminating the need for multiple specialized molds.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The floor structure allows for flexible arrangement of underfloor devices by positioning receiving members at appropriate locations along the longitudinal direction. The modular nature of the receiving members enables adaptation to different device configurations without requiring complete redesign of the floor structure.

Inventive Principle:

Principle #15Dynamics

3Volume of moving object

If a corrugated plate is arranged inside the underframe, then the height of the upper surface of the floor can be lowered, but the floor receiver cannot adequately support passenger loads

Engineering Contradiction:

Improveinner spaceVSAvoidload support capacity

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The receiving members act as intermediary structures between the supporting members and the floor panels. They transfer passenger loads from the floor panels through their leg portions to the supporting members, which in turn transfer loads to the cross beams. This intermediary structure enables adequate load support while maintaining a low floor profile.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The floor structure combines multiple materials and components: supporting members providing structural stiffness, receiving members for load transfer, and floor panels for the finished surface. This composite approach allows the structure to achieve both low height and high load-bearing capacity by optimizing each component's function.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9533692B2Floor structure of railcar and railcar including same

Publication Date: 2017.01.03 KAWASAKI RAILCAR MFG CO LTD

AI summary

A floor structure of a railcar includes: a pair of side sills extending in a railcar longitudinal direction; cross beams extending in a railcar width direction and coupling the pair of side sills; a supporting member, which is arranged on upper surfaces of the cross beams, in which bottom surface portions and convex portions projecting upward from the bottom surface portions are alternately, continuously formed in the railcar width direction, and which extends in the railcar longitudinal direction; receiving members located at positions corresponding to the cross beams, arranged on an upper surface of the supporting member, and extending in the railcar width direction; and a floor panel arranged on upper surfaces of the receiving members. The receiving members include: a floor plate contact portion that contacts the floor panel; and leg portions, extending from the floor plate contact portion to the bottom surface portion of the supporting member.