Universal Backing Ring One-Piece Design for Railcar Axles
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Solution Overview
Problem
Existing universal backing rings for railcar axles have a two-piece construction, leading to increased manufacturing, production, and assembly costs, and are limited in their ability to fit railcar axles with varying diameters.
Innovation Solution
A one-piece, integrally formed universal backing ring with an annular structure that includes a dust guard lip and a relief groove, allowing for a mechanical interference fit with the dust guard of a railcar axle, and made from materials like ductile iron or steel to facilitate deflection and fit various axle diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a two-piece construction is used for universal backing rings, then the ability to fit railcar axles with varying diameters is improved, but manufacturing and assembly costs increase
Solution Approach 1:
The patent combines the rigid ring portion and the sealing/stabilizing element into a single integrally formed backing ring. This merging eliminates the need for separate manufacturing and assembly of two pieces, reducing costs while maintaining the universal fit capability through the integrated design that includes a dust guard engaging lip and contoured inner surface.
2Manufacturing precision
If a fitted backing ring is used for new railcar axles, then the fit precision is improved, but the usability after axle wear is reduced
Solution Approach 1:
The patent designs the backing ring with a universal fit capability that works for both new and worn railcar axles. The contoured inner surface and dust guard engaging lip are designed to accommodate a range of axle diameters within a class, allowing the same backing ring to provide precise fit for new axles and continue to function effectively after axle wear occurs.
3Ease of manufacture
If a one-piece design is used for backing rings, then manufacturing costs are reduced, but the ability to provide both structural support and sealing may be compromised
Solution Approach 1:
The patent applies local quality by designing specific features on the one-piece backing ring: a dust guard engaging lip for sealing functionality, a contoured inner surface for structural support and positioning, and appropriate material selection. These localized features ensure that the single piece provides both structural support and sealing capabilities equivalent to two-piece designs.
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 one-piece design reduces manufacturing costs and allows the universal backing ring to fit railcar axles within a specific Class, accommodating a range of diameters without the need for multiple pieces, thus enhancing versatility and cost-effectiveness.
Implementation Method 1
The annular structure is made from material exhibiting a predetermined stiffness allowing portions of the annular structure to deflect, facilitating the mechanical interference fit with the dust guard
Data Source
AI summary
Embodiments relate to a one-piece, integrally formed universal backing ring comprising an integrally formed, one piece annular structure having a center opening configured to be translated over a journal of a railcar axle and engage a dust guard and a dust guard fillet of the railcar axle. The annular structure includes an inner contoured surface having a profile that is contoured for a tight surface fit with a complementary surface of the dust guard fillet. The annular structure also includes a dust guard lip which projects over the dust guard fillet and engages the dust guard. The dust guard lip has a length extending generally parallel with an axis of the annular structure, and is configured to provide a mechanical interference fit of the dust guard lip with the dust guard of 0.052-0.1875 inches with a maximum diameter of the dust guard for each Class of railcar axle.