Optimization of a central beam for a modular freight wagon concept

Abstract

A future-proof rail freight wagon needs to adapt to customer needs, at time of purchase as well as during its lifetime. A solution for this challenge is a new type of freight wagon concept complying with European standards, which features two head stocks connected via a modular and length-variable (1 500 to 13 360 mm) central beam. The central beam consists of different modules which can be freely placed and combined along its length. Certain modules feature connection points for cross beams on which custom load units or freight containers can be mounted. First, this paper describes the three stages of topology optimization used to improve the initial design of the central beam: (1) optimization of the central beam with abstract representations of cross beams, (2) optimization of the cross beams using the optimized central beam, (3) final optimization of the central beam using the optimized cross beams. This leads to a fully optimized design proposal which, is then detailed, analyzed and will ultimately be manufactured according to customer requirements starting from 2022 for operation on the European rail network.