Segmented Railcar Cover for Dust Containment and Weight Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Uncovered railcars, particularly those transporting coal, pose environmental and maintenance challenges due to coal dust, with existing covers being heavy and cumbersome, and methods like dusting agents or grooming failing to effectively contain dust.

Innovation Solution

A railcar cover system with structural members that can move between loading, unloading, and covered positions, featuring cover portions coupled to these members to provide effective dust containment, reduced weight, and improved aerodynamics, allowing for easy loading and unloading by machines like coal tipples and rotary dumpers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional fiberglass covers are used to contain coal dust, then dust containment is improved, but the cover weight increases making it cumbersome to use

Engineering Contradiction:

Improvecoal dust containmentVSAvoidcover weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The cover is divided into multiple panels that can be independently positioned and secured. Each panel is a separate component that can be easily handled and installed, reducing the overall cumbersome nature while maintaining effective dust containment across the entire railcar surface

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover system incorporates movable panels that can be dynamically positioned during loading and unloading operations. The panels can be opened, closed, and secured at different positions along the railcar, providing adaptability for various operational modes while maintaining a lightweight structure compared to conventional fixed covers

Inventive Principle:

Principle #15Dynamics

2Object-affected harmful factors

If a heavy conventional cover is used to contain dust, then dust containment is improved, but the railcar cargo weight capacity decreases

Engineering Contradiction:

Improvecoal dust containmentVSAvoidcargo weight capacity

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The segmented panel design allows for effective dust containment using lighter materials and smaller individual components, collectively providing full coverage without the excessive weight of conventional monolithic covers, thereby preserving cargo weight capacity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover panels utilize flexible, thin-walled structures that provide effective dust containment barriers while minimizing weight. These thin film-like panels can be easily positioned and secured, achieving the same containment function as heavy conventional covers but with significantly reduced weight that preserves cargo capacity

Inventive Principle:

Principle #30Flexible shells and thin films

3Device complexity

If a fixed cover structure is used, then structural simplicity is maintained, but the ability to accommodate different loading and unloading operations is reduced

Engineering Contradiction:

Improvecover structure simplicityVSAvoidloading and unloading adaptability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cover panels are designed to perform multiple functions: they can be positioned to accommodate different loading methods (front-end loaders, conveyors), different unloading methods (rotary dumpers, side-dump mechanisms), and provide dust containment during transport. This multi-functionality is achieved through a relatively simple panel and rail structure that offers versatile operational capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9145150B2Railcar cover

Publication Date: 2015.09.29 TRINITY INDUSTRIES INC

AI summary

A system for covering a railcar includes a first set and a second set of structural members coupled to a railcar. The structural members are configured to move between a loading position, an unloading positing, and a covered position. The system includes a plurality of cover portions, each coupled to a structural member of the first set and a structural member of the second set. In the loading position, at least one of the first set and at least one of second set are proximate longitudinal sides of the railcar. In the unloading position, at least one of the first set and at least one of second set are proximate a longitudinal center line of the railcar. In the covered position, the first set are proximate the longitudinal center line of the railcar, and the second set are proximate the longitudinal sides of the railcar.