United States Department of Transportation
i
A crush zone design for an existing passenger rail cab car
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2005-11-05
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[PDF-1.46 MB]
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Alternative Title:2005 ASME International Mechanical Engineering Congress & Exposition, November 5-11, 2005, Orlando, FL
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Abstract:A Crash Energy Management (CEM) cab car crush zone
design has been developed for retrofit onto an existing Budd
M1 cab car. This design is to be used in the upcoming fullscale
train-to-train test of a CEM consist impacting a standing
freight consist of comparable weight. The cab car crush zone
design is based upon the coach car crush zone design that has
been previously developed and tested.
The integrated system was developed after existing national
and international CEM systems were reviewed. A detailed set
of design requirements was then drafted, and preliminary
designs of sub-assemblies were developed. The preliminary
designs were analyzed using detailed large deformation finite
element software. Performance of the cab car crush zone under
ideal and non-ideal loading conditions was analyzed prior to
development of the final design.
The key components of the design include: a long stroke
push-back coupler capable of accommodating the colliding
locomotive coupler, a deformable anti-climber to manage the
colliding interface interaction, an integrated end frame on
which the deformable anti-climber is attached, a set of primary
energy absorbers designed to crush in a controlled manner
while absorbing the majority of the collision energy, and a
survivable space for the operator which pushes back into an
electrical closet.
The cab car crush zone is designed to control both lateral and
vertical vehicle motions that can promote lateral buckling of the
train and override of the impacting equipment. The design is
capable of managing the colliding interface interaction with a
freight locomotive and passing crush back to successive crush
zones. Detailed fabrication drawings have been developed and
submitted to a fabrication shop. In addition, existing Budd M1
cars are being prepared to receive the retrofit components.
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