Railgear Frame Bar Assembly With Electric Actuation and Interference Fit
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Solution Overview
Problem
Conventional railgear systems for hi-rail vehicles are heavy, reducing payload capacity and requiring significant torque to rotate, and rely on hydraulic cylinders that necessitate additional components and power, making them inefficient.
Innovation Solution
A vehicle frame system with a frame bar and sleeves made of different materials, where the sleeves are interference fit with the frame bar and guide tubes, allowing for controlled temperature changes to assemble and secure the components, reducing weight and power requirements, and using electric actuators for efficient movement between rail and non-rail states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional steel railgear systems are used, then structural strength and durability are improved, but vehicle weight increases and payload capacity decreases
Solution Approach 1:
The patent employs composite material construction by combining aluminum alloy frame bars with steel sleeves at critical connection points. The aluminum alloy provides lightweight structural strength while the steel sleeves reinforce high-stress areas, achieving an optimal balance between overall strength and weight reduction for the railgear system
Solution Approach 2:
The patent applies local quality enhancement by selectively placing steel sleeves only at the frame bar ends where connection to guide assemblies occurs. This localized reinforcement provides maximum strength where needed while keeping the majority of the structure lightweight, rather than using uniform heavy steel construction throughout
2Force
If hydraulic cylinders are used to control frame bar rotation, then sufficient torque is achieved, but device complexity and power requirements increase
Solution Approach 1:
The patent extracts and eliminates the hydraulic system entirely from the railgear assembly. By removing the hydraulic cylinder, pumps, manifolds, hoses, and associated power requirements, the invention achieves frame bar rotation control through purely mechanical means, dramatically reducing system complexity while maintaining adequate torque through the electric actuator and mechanical advantage of the guide assembly geometry
Solution Approach 2:
The patent replaces the hydraulic mechanical system with an electric actuator system. The electric actuator directly drives the frame bar rotation through the guide assembly, substituting hydraulic fluid pressure and complex valve mechanisms with electric motor torque and simplified mechanical linkages, thereby reducing both complexity and power system requirements
3Manufacturing precision
If interference fit sleeves are used to secure components, then assembly precision and structural integrity are improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes through thermal expansion and contraction of the aluminum alloy frame bars. By heating the frame bar during assembly, the aluminum expands to allow insertion of steel sleeves; upon cooling, the aluminum contracts to create a tight interference fit. This controlled parameter change enables precise assembly without requiring complex manufacturing processes or specialized equipment
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 system reduces weight and power consumption, enhances payload capacity, and improves efficiency by allowing the vehicle to seamlessly transition between rail and non-rail operations without the need for extensive hydraulic systems.
Implementation Method 1
The first sleeve is configured for a temperature of the first sleeve to be controlled to change one or more characteristics of the first sleeve
Data Source
AI summary
A vehicle frame assembly includes a frame bar extending between first and second ends along a first axis. The first end is coupled with a first guide assembly, and the second end of the frame bar is coupled with a second guide assembly. First and second housings are coupled with a frame of a vehicle system. A first actuator system extends between the first housing and the frame bar, and a second actuator system is extends between the second housing and the frame bar. The first and second actuator systems control rotational movement of the frame bar between first and second directions of rotation. Rotating the frame bar in the first direction of rotation moves an axle away from a route, and rotating the frame bar in the second direction of rotation moves the axle toward the route.