Railcar Side Rail Section With Variable Web Geometry

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Solution Overview

Problem

Existing longitudinal beams for rail vehicles face challenges in material utilization, weight, dimensions, and space utilization due to uniform cross-sections, leading to oversizing, unfavorable stress situations, and geometric incompatibilities.

Innovation Solution

A longitudinal beam part with a cross-sectional profile featuring first and second longitudinal webs and optional third web, manufactured using pressure forming, with the third web removed in specific sections to optimize material use and enable precise connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If aluminum profiles are manufactured by extrusion with uniform cross-section, then manufacturing simplicity is maintained, but material utilization is inefficient and weight increases

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidlongitudinal beam weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The longitudinal beam is divided into multiple sections along its length, with each section having a different cross-sectional geometry optimized for its specific load conditions. This segmentation allows the beam to have varying thickness and structural characteristics in different regions, reducing overall weight while maintaining strength where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the longitudinal beam are given different local geometries and material distributions according to their specific functional requirements. High-stress areas receive reinforced structures while low-stress areas use thinner sections, optimizing material utilization and reducing unnecessary weight.

Inventive Principle:

Principle #3Local quality

2Device complexity

If uniform cross-section is used along the longitudinal beam, then manufacturing complexity is reduced, but connection areas cannot be adapted to different adjacent parts causing geometric incompatibilities

Engineering Contradiction:

Improvebeam geometry complexityVSAvoidconnection area adaptability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The beam is segmented into different sections, each with customized connection areas designed to match specific adjacent components. This allows each section to have optimized connection geometries while the overall manufacturing process remains manageable through modular production approaches.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Connection areas are given specialized local geometries tailored to their specific mating components. Each connection zone is designed with the precise shape, size, and features needed for optimal assembly with adjacent parts, improving adaptability without requiring complete redesign of the entire beam.

Inventive Principle:

Principle #3Local quality

3Productivity

If extrusion process is used for manufacturing, then production efficiency is high, but design flexibility is limited due to uniform cross-section requirement

Engineering Contradiction:

Improveproduction efficiencyVSAvoiddesign flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The longitudinal beam is divided into multiple sections that can be manufactured separately using extrusion processes, then assembled together. This segmentation allows each section to be produced efficiently while maintaining design flexibility for varying cross-sections in different regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cross-sectional parameters of the beam are varied along its length to optimize performance for different load conditions. By changing geometric parameters such as thickness, width, and reinforcement patterns in different sections, the design achieves both flexibility and manufacturing efficiency.

Inventive Principle:

Principle #35Parameter changes

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

Enhances material efficiency, reduces weight, optimizes space, and prevents geometric incompatibilities while providing stable connections, improving bending stiffness and stress distribution.

Implementation Method 1

manufactured using a pressure forming process

Methodology Applied

Scientific EffectPressure forming: Compression

Data Source

PatentEP4273016B1Side rail section for a car body of a railway vehicle

Publication Date: 2026.02.25 ALSTOM HOLDINGS SA

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AI summary

A longitudinal beam component (LT) for a car body (W) of a rail vehicle is proposed, wherein the longitudinal beam component (LT) is manufactured using a pressure forming process, wherein the longitudinal beam component (LT) has a first longitudinal section (LA1) in which a first longitudinal web (1), a second longitudinal web (2) and a third longitudinal web (3) are arranged next to each other when viewed in a cross-section such that - the first longitudinal web (1) and the second longitudinal web (2) as well as - the second longitudinal web (2) and the third longitudinal web (3) each overlap at least partially, wherein the second longitudinal web (2) is arranged between the first longitudinal web (1) and the third longitudinal web (3), wherein the longitudinal beam component (LT) has a second longitudinal section (LA2) in which the third longitudinal web (3) is removed.Furthermore, a car body (W) with the longitudinal beam part (TR), a manufacturing process for the longitudinal beam part (TR) and a manufacturing process for a car body (W) with the longitudinal beam part (TR) are proposed.