Torque Box With Segmented Bottom Surface for Railcar Stress Reduction

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Solution Overview

Problem

Existing railcar designs face increased stress and potential failure due to the weight and vertical offset of conventional torque boxes, which can lead to structural issues when transporting heavy freight, as they require clearance for wheel structures, increasing the moment arm and stress on the railcar.

Innovation Solution

A lowerable torque box design with a corrugated bottom surface that reduces vertical offset and weight, allowing clearance for wheel structures while acting as a structural component and efficient force transmission system, thereby reducing stress on the railcar.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a conventional torque box is used to control stress on railcar segments, then stress control is improved, but the vertical offset from the railcar increases the moment arm and thus increases stress on the railcar

Engineering Contradiction:

Improvestress controlVSAvoidstress on railcar

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The torque box is repositioned from a vertically offset configuration to a configuration where it is lowered and positioned closer to the wheel structures, changing the spatial dimension of its placement. This dimensional change reduces the moment arm and thereby reduces the stress on the railcar while maintaining stress control functionality

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Stress or pressure

If the torque box is lowered to reduce vertical offset, then stress on the railcar is reduced, but clearance for wheel structures is compromised

Engineering Contradiction:

Improvestress on railcarVSAvoidclearance for wheel structures

Core Design Contradiction:

Stress or pressureVSEase of operation

Solution Approach 1:

The bottom surface of the torque box is segmented into raised portions and recessed portions. The recessed portions create clearance spaces that accommodate the wheel structures, allowing the torque box to be lowered closer to the wheels without compromising operational clearance

Inventive Principle:

Principle #1Segmentation

3Strength

If a shear plate design is used to transfer stress between railcar portions, then stress transfer is improved, but the design becomes heavy and costly to manufacture

Engineering Contradiction:

Improvestress transferVSAvoidweight of stress transfer mechanism

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The torque box is designed to perform multiple functions: it controls stress on railcar segments, transfers stress between portions, and provides structural support. By consolidating these functions into a single component rather than using separate shear plates, the overall weight and manufacturing cost are reduced while maintaining stress transfer capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11198454B2Torque box

Publication Date: 2021.12.14 TRINITY RAIL GROUP LLC

AI summary

A torque box includes a front plate and a bottom surface. The bottom surface is coupled to the front plate such that the bottom surface is orthogonal to front plate and such that front plate extends along the bottom surface. The bottom surface defines a first raised portion configured to fit over a wheel of a railcar.