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Design and Analysis of Robust Modular Cantilevers for Railway Overhead Applications: A Failure Prevention Approach

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Abstract

This paper highlights the development and validation of two innovative modular cantilever (MC) designs for railway overhead applications. Existing MCs are heavy, complex, and prone to failures. Addressing these shortcomings, the proposed designs leverage topology optimization and TRIZ principles to achieve significant improvements: weight reduction: Up to 28% lighter than existing MCs due to optimized material distribution. Enhanced robustness: Improved structural efficiency and strength, reducing failure risk. Simplified assembly and maintenance: fewer components and modular design facilitate easier handling and installation. Environmental resistance: increased durability against fatigue cracking, corrosion, and wear and tear. Numerical calculations and finite element analysis validate the performance of the new designs, confirming their ability to withstand dynamic loading conditions equivalent to traditional MCs. These lightweight, robust, and adaptable solutions offer tremendous potential for reducing costs, improving safety, and optimizing performance in railway overhead applications.

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Abbreviations

OCL:

Overhead contact line

OCS:

Overhead catenary system

MCS:

Modular cantilever system

MC:

Modular cantilever

OHE:

Overhead equipment

FRP:

Fiber reinforced polymer

FEA:

Finite element analysis

FEM:

Finite element method

RDSO:

Research Designs & Standards Organization

TRIZ:

Theory of inventive problem solving

GFRP:

Glass fiber reinforced plastic

MMA:

Method of moving asymptotes

TO:

Topology optimization

SIMP:

Solid isotropic material with penalization

ISO:

International Organization for Standardization

CAD:

Computer aided design

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Acknowledgments

This research and development work was supported by Raychem Innovation Center (RIC) of Raychem RPG Ltd. We would like to express our gratitude to Dr. Sudhakar Reddy, Chief Scientist of ‘Material and Processing Center of Excellence’ of RIC for his significant guidance in this research work. We thank our colleague Kaushik Patel who provided expertise that greatly help the research to go in right direction. Two patents have been filed on these novel modular cantilevers with an application number 21037528 and 201821032447 for optimized and foldable MC respectively.

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Authors and Affiliations

  1. Material and Processing Department, Raychem Innovation Centre, Halol, Gujarat, India

    Vishal Patil, Ishant Jain, Raghav Upasani, Ganesh Bhoye & Sumit Zanje

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  1. Vishal Patil
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  2. Ishant Jain
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  3. Raghav Upasani
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Correspondence to Ishant Jain.

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Patil, V., Jain, I., Upasani, R. et al. Design and Analysis of Robust Modular Cantilevers for Railway Overhead Applications: A Failure Prevention Approach. J Fail. Anal. and Preven. 24, 1148–1165 (2024). https://doi.org/10.1007/s11668-024-01903-z

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