LIGHTWEIGHT UNDERFRAME FOR MACHINE

TECHNICAL FIELD

[0001] The present disclosure relates generally to an underframe for a machine, and, more particularly, to a lightweight underframe for a machine.

BACKGROUND

[0002] Machines like railroad locomotives are typically very heavy, weighing several hundred tons. All of the machine weight is supported on the railroad tracks by the traction devices, which typically include a plurality of bogies. Each bogie may include two or more axles, each axle supporting a pair of wheels on opposite ends of the axle. Structural and safety considerations limit the maximum weight that can be supported by each axle. As a result, the greater the weight of the machine, the larger the number of axles needed to support the weight of that locomotive.

[0003] Conventional combustion engine driven locomotives may have a weight of the order of several thousand tons. Electrically operated locomotives require a large number of battery modules to deliver the same amount of power. The weight of the battery modules may increase the weight of a battery operated locomotive by as much as 30 to 40% over the weight of a conventional combustion engine driven locomotive. The weight of the locomotive affects fuel efficiency because a heavier locomotive may consume more fuel to propel the locomotive and more energy may be required for braking the locomotive. Thus, there is a desire to decrease the weight of a locomotive, especially a battery driven locomotive, to improve fuel efficiency.

[0004] Additionally, the maximum weight that can be imposed on the railroad track is limited by structural and safety considerations. As also discussed above, the maximum weight that can be supported by each axle is also limited by structural and safety considerations. Each axle may be associated with springs, shock absorbers, braking mechanisms, electric motors, fasteners, and/or other components. Thus, increasing the number of axles to support the machine weight results in a significant increase in the number of components that may require repair or replacement during the life of the machine, which in turn may increase the cost of operating the machine. Therefore, there is also a desire to minimize the weight of the locomotive to correspondingly reduce the weight supported by each axle and the number of axles required to support the weight of the locomotive. For example, it may be preferable to provide a locomotive with two bogies, each with a pair of axles supporting the weight of the entire locomotive.

[0005] Contributors to the total locomotive weight typically include the underframe or chassis of the locomotive, the operator’s cabin and associated equipment, the prime mover and its associated components, fuel, water, and/or any other materials or equipment required for the operation of the locomotive. The prime mover may include a combustion engine, for example, a diesel engine, a gasoline engine, a natural gas engine, or a hybrid fuel engine. However, to address the environmental effect of exhaust gases and other emissions from combustion engines, the combustion engine may be replaced or supplemented by one or more electrical motors. Such electric motors are typically powered by one or more battery modules that may be accommodated on the underframe of the machine.

[0006] The operator’s cabin and associated equipment typically contribute the least amount of weight, whereas the prime mover, such as a combustion engine or the battery modules, electric motors, and associated components may account for most of the weight of the locomotive. For example, as discussed above, use of battery modules may increase the locomotive weight by nearly 30 to 40% over the weight of a conventional combustion engine driven locomotive. The weight of the prime mover and associated components and fuel may be dictated by the amount and duration of propulsive power required during operation of the locomotive. Thus, one way to compensate for the increase in locomotive weight due to, for example, the higher weight of the battery modules, is to reduce the weight of the underframe. The underframe, however, supports the weight of the prime mover when the locomotive is at rest, and must also be capable of handling dynamic loads and stresses induced when the locomotive is moving at high speed and/or negotiating curves. Thus, reductions in weight of the underframe must be performed judiciously to ensure that the underframe can support the weight of the locomotive components and can also withstand the static and dynamic stresses exerted on the underframe.

[0007]International Patent Publication No. AT408334B was published on October 25, 2001 (“the AT334 publication”), and discloses an underframe for a railroad vehicle. The AT334 publication discloses that the total weight of the vehicle consists of the deadweight and the payload. The AT334 publication also discloses that since the majority of the vehicle’s own weight is made up of the underframe, the aim is to reduce the weight of the underframe of the rail vehicle. Towards that end, the AT334 publication discloses an undercarriage that has two longitudinal beams. Each longitudinal beam has an I-profile with one lower flange, one upper flange, and at least one web which connects the lower and upper flanges. The AT334 publication discloses that the two longitudinal beams are connected to each other via at least one cross element having an I- or U-shaped cross-section. Further the AT334 publication discloses that the web in the longitudinal beams is corrugated. The AT334 publication also discloses that fastening of the cross beams to the longitudinal beams is made possible because the longitudinal beams have gusset plates that are attached to the upper flanges and upper sections of the webs of the longitudinal beams, and welded to the cross beams.

[0008] Although the AT334 publication discloses an underframe design that may have a lower weight, the underframe of the AT334 publication may still be suboptimal. For example, because the gusset plates are attached only to the upper sections of the I-beam webs, the upper and lower flanges of the longitudinal beams of the AT334 publication may not provide sufficient rigidity. Thus, the upper and/or lower flanges of the longitudinal beams of the AT334 publication may be subject to significant bending due to the weight of the components supported by the underframe both when the locomotive is at rest and when the locomotive is negotiating curves at high speed. Such bending of the flanges may cause undesirable movement and/or vibrations in the components supported by the underframe. Furthermore, the stresses induced in the upper and lower flanges due to the insufficient rigidity of the underframe may reduce the operational life of the underframe and the locomotive.

[0009] The lightweight underframe of the present disclosure solves one or more of the problems set forth above and/or other problems of the prior art.

SUMMARY

[0010] In one aspect, the present disclosure is directed to an underframe for a machine. The underframe may include a first beam extending in a longitudinal direction. The underframe may also include a second beam disposed generally parallel to the first beam and spaced apart from the first beam in a transverse direction. At least one of the first beam and the second beam may include a lower plate, an upper plate, and a web extending between the lower plate and the upper plate. The underframe may also include at least one cross beam extending in the transverse direction. The cross beam may be attached to the first beam and the second beam. Further, the underframe may include at least one bracket aligned with the at least one cross beam in the transverse direction. The at least one bracket may include a first leg extending along the web from the lower plate to the upper plate, the first leg attached to the lower plate and the web. The at least one bracket may also include a second leg extending from the first leg, the second leg attached to the upper plate. The at least one bracket and the at least one cross beam may be disposed on opposite sides of the web.

[0011] In another aspect, the present disclosure is directed to an underframe. The underframe may include a first beam and a second beam both extending generally parallel to each other in a longitudinal direction and spaced apart from each other in a transverse direction. Each of the first beam and the second beam may include a lower plate, an upper plate, and a web extending between the lower plate and the upper plate. The underframe may include a plurality of cross beams extending in the transverse direction and connected to the first beam and the second beam. The underframe may also include a plurality of first brackets, each of the first brackets being in transverse alignment with a respective cross beam of the cross beams. Further, the underframe may include a plurality of second brackets, each of the second brackets in transverse alignment with the respective cross beam. Each of the first brackets may include a first leg extending along the web from the lower plate of the first beam to the upper plate of the first beam, the first leg attached to the web of the first beam. Each of the first brackets may also include a second leg attached to the upper plate of the first beam, the second leg and the respective cross beam being disposed on opposite sides of the web of the first beam. Each of the second brackets may include a third leg extending along the web from the lower plate of the second beam to the upper plate of the second beam, the third leg attached to the web of the second beam. Each of the second brackets may also include a fourth leg attached to the upper plate of the second beam, the fourth leg and the respective cross beam being disposed on opposite sides of the web of the first beam.

[0012] In yet another aspect, the present disclosure is directed to a locomotive. The locomotive may include an underframe extending in a longitudinal direction. Further, the locomotive may include a plurality of bogies including wheels configured to support the underframe on a track. The locomotive may also include an operator cabin disposed at one end of the underframe. The locomotive may include one or more components of a prime mover positioned on the underframe between the operator cabin and an opposite end of the underframe. The prime mover may be configured to propel the wheels. The underframe may include a first I-beam and a second I-beam extending generally parallel to each other in the longitudinal direction and spaced apart from each other in a transverse direction. Further, the underframe may include a plurality of cross beams extending in the transverse direction and connected to the first I-beam and the second I-beam. The underframe may also include a plurality of first L-shaped brackets. Each first bracket of the first L-shaped brackets may be attached to a first web of the first I-beam and to a first upper plate of the first I-beam. The first bracket and a respective cross beam of the cross beams may be disposed on opposite sides of the first web. The underframe may also include a plurality of second L-shaped brackets. Each second bracket of the second L-shaped brackets may be attached to a second web of the second I-beam and to a second upper plate of the second I-beam. The second bracket and the respective cross beam may be disposed on opposite sides of the second web.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a diagrammatic illustration of an exemplary disclosed machine;

[0014]FIG. 2 is a diagrammatic illustration of an exemplary underframe of the machine of FIG. 1;

[0015]FIG. 3 is a diagrammatic illustration of a cross-section taken along line A-A of the underframe of FIG. 2;

[0016]FIG. 4 is a magnified partial view of the cross-section of FIG. 3;

[0017]FIG. 5 is another magnified partial view of the cross-section of FIG. 3;

[0018]FIG. 6 is diagrammatic partial perspective view showing the cross-section of FIG. 3;

[0019]FIG. 7 is a diagrammatic illustration of machine components assembled to the underframe of FIG. 2; and

[0020]FIG. 8 is a diagrammatic illustration of a magnified portion the underframe of FIG. 7.

DETAILED DESCRIPTION

[0021]FIG. 1 illustrates an exemplary embodiment of machine 10. Machine 10 may be a mobile machine that performs some type of operation associated with an industry such as the railroad industry or another industry known in the art. For example, machine 10 may be a locomotive designed to pull rolling stock. In some embodiments, machine 10 may include rolling stock (e.g., passenger or goods cars or wagons) other than a locomotive. It is also contemplated that machine 10 may include machines in other industries, for example, trucks, loaders, or any other type of construction, earthmoving, or other machinery. Machine 10 may include underframe (or chassis) 12 that may be supported by one or more traction devices 14. In one exemplary embodiment as illustrated in FIG. 1, traction devices 14 may be in the form of bogies 14 that may support underframe 12 on railroad track 16. Bogies 14 may have one or more axles 18, each of which may include a pair of wheels 20 positioned at opposite ends of axles 18. Wheels 20 may be configured to roll along railroad track 16.

[0022]Machine 10 may include operator cabin 22 positioned adjacent to front end 42 of underframe 12. In some exemplary embodiments, machine 10 may additionally include storage compartment 24 positioned at an opposite end, adjacent to rear end 44, of underframe 12. Operator cabin 22 may include one or more controlled devices configured to allow an operator of machine 10 to control one or more operations of machine 10. Storage compartment 24 may allow for storage of auxiliary equipment or may provide facilities for the operator of machine 10.

[0023] Machine components 26 associated with one or more prime movers for machine 10 may be disposed on underframe 12. For example, the prime mover may include one or more combustion engines, or a hybrid-powered engine including one or more combustion engines and one or more electric engines that may individually or in combination provide power for propulsion and operation of machine 10. Alternatively, the prime mover may include a fully electric engine, including one or more electric motors that may provide power for propulsion and operation of machine 10. The prime mover may be configured to propel the one or more wheels 20 and deliver power to operate one or more other accessory devices (e.g. pumps, fans, motors, generators, belt drives) associated with machine 10.

[0024]In one exemplary embodiment as illustrated in FIG. 1, machine components 26 may include a plurality of battery modules 28 that may be configured to supply electrical power to one or more electrical motors of an electric engine of machine 10. As also illustrated in the exemplary embodiment of FIG. 1, battery modules 28 may include a plurality of full-size battery modules 30 and a plurality of partial-size battery modules 32. The number and arrangement of full-size battery modules 30 and partial-size battery modules 32 illustrated in FIG. 1 is exemplary and nonlimiting. For example, machine components 26 may include any number of full-size battery modules 30, any number of partial-size battery modules 32, or any combination thereof. The number of full-size battery modules 30 and/or partial size battery module 32 may be determined by a desired amount of motive power for machine 10.

[0025]FIG. 2 illustrates an exemplary underframe 12 of machine 10. Underframe 12 may extend from adjacent front end 42 to adjacent rear end 44. As used in this disclosure the terms front end rear should be understood to express directions relative to each other. For example, machine 10 when moving in a forward direction moves in a direction extending from rear end 44 towards front end 42 (e.g., -X direction), and when moving in a rearward direction moves in a direction extending from front end 42 towards rear end 44 (e.g., +X direction).

[0026]Underframe 12 may include beams (e.g., longitudinal beams) 46 and 48 disposed generally parallel to each other and extending along a longitudinal direction (e.g., +X or -X direction) of underframe 12. Longitudinal beam 46 may extend from adjacent front end 42 to adjacent rear end 44 along the longitudinal direction. Similarly, longitudinal beam 48 may extend from adjacent front end 42 to adjacent rear end 44 along the longitudinal direction. Longitudinal beam 46 may be spaced apart from longitudinal beam 48 in a transverse direction (e.g., +Y or -Y direction) by gap 50 that may extend along an entire length of longitudinal beam 46 and/or longitudinal beam 48. Gap 50 may allow for placement of passageways, ducts (e.g., air cooling or water cooling ducts), pipes (e.g., Water, fuel, and/or other fluid pipes), electrical wiring, and/or auxiliary equipment associated with the one or more prime movers of machine 10. In some embodiments, gap 50 may allow for placement of one or more components, equipment, or other materials being carried by a railroad vehicle or any other machine 10 Although only two longitudinal beams 46 and 48 have been illustrated in FIG. 2 and described above, underframe 12 may include any number of longitudinal beams 46 and 48 extending along the longitudinal direction (e.g., +X or -X direction) and spaced apart from each other in the transverse direction (e.g., +Y or -Y direction).

[0027]In some exemplary embodiments as illustrated in FIG. 2, end frame 52 may be attached to beams 46 and 48 adjacent to front end 42, and end frame 54 may be attached to beams 46 and 48 adjacent to rear end 44. End frames 52 and 54 may include one or more coupling devices (not shown) that may allow machine 10 to be connected to other rolling stock such as railroad wagons and/or to other machines 10.

[0028]One or more cross beams 56 may extend between longitudinal beams 46 and 48. Opposite ends of the one or more cross beams 56 may be attached to longitudinal beams 46 and 48. Cross beams 56 may extend in a transverse direction (e.g., +Y or -Y direction) relative to longitudinal beams 46 and/or 48. In some exemplary embodiments, cross beams 56 may be disposed generally parallel to each other and generally perpendicular to longitudinal beams 46 and 48. In other exemplary embodiments, cross beams 56 may be inclined relative to each other and/or relative to longitudinal beams 46 and 48.

[0029]As used in this disclosure the term generally or about should be interpreted to encompass commonly understood design and manufacturing tolerances. For example “generally perpendicular” may encompass angles in the range of 90° ± 5°. Similarly, for example, “generally parallel” may encompass angles in the range of 0° ± 5°. Likewise, “generally inclined” may encompass angles ranging between 5° and 85°. As another example, “about 15 mm” may encompass lengths of 15 mm ± 1 mm. Additionally, the terms “attached” or “connected” refer to direct or indirect joining of components without allowing for relative movement between the joined components. Indirect joining may refer to joining of components with one or more other components located between the joined components. Components that are attached or connected may be joined, using fasteners, rivets, welding, brazing, adhesives, or any other method of attachment known in the art.

[0030] A spacing between adjacently located cross beams 56 (e.g., in the longitudinal or +X or -X directions) may be uniform or nonuniform. For example, a gap between a first pair of adjacently located cross beams 56 may be smaller than a gap between a second pair of adjacently located cross beams 56 by at least 5%, 10%, 15%, 20%, or by any other amount. In some embodiments, cross beam 56 may be a rectangular cross beam, having a generally annual rectangular cross section. In other embodiments cross beam 56 may have a square, triangular, circular, elliptical or any other cross-sectional shape. It is also contemplated that in some exemplary embodiments cross beam 56 may be an I- shaped, T -shaped, L- shaped, C- shaped, or U- shaped beam. It is also contemplated that some or all cross beams 56 in underframe 12 may have the same or different cross-sectional shapes.

[0031]As illustrated in FIG. 2, in some exemplary embodiments, one or more wings 58 may extend from one or both sides of cross beams 56 along the longitudinal direction (e.g., +X or -X direction). Wings 58 attached to a particular cross beam 56 may be spaced apart from each other in the transverse direction (e.g., +Y or -Y direction). Wings 58 may include one or more openings 66 (see FIG. 3) configured to receive fasteners that may be used to attach one or more of machine components 26 to underframe 12. Although two wings 58 extending from each cross beam 56 have been illustrated in FIG. 2, any number of wings 58 may project from each cross beam 56. Furthermore, the spacing between wings 58 on a particular cross beam 56 may be uniform or nonuniform. Similarly, the spacing between wings 58 on different cross beams 56 may be uniform or nonuniform.

[0032]As also illustrated in FIG. 2, in some exemplary embodiments, one or more cross plates 60 may extend between and may be connected to longitudinal beams 46 and 48 nearer to front end 42 and/or rear end 44. In some exemplary embodiments, a thickness of cross plate 60 may be about 48 mm to 52 mm. Compare this with a thickness of about 72 mm to 78 mm of cross plates used on conventional underframes. Front cover plate 62 may be disposed adjacent to front end 42. Front cover plate 62 may cover gap 50 between longitudinal beams 46 and 48 and may form a floor for operator cabin 22. Likewise, rear cover plate 64 may be disposed adjacent to rear end 44. Rear cover plate 64 may cover gap 50 between longitudinal beams 46 and 48 and may form a floor for storage compartment 24. Although not shown in FIG. 2, underframe 12 may include one or more other cover plates that may cover gap 50 and may be disposed between front cover plate 62 and rear cover plate 64.

[0033]FIG. 3 illustrates a vertical cross section of underframe 12 taken along line A-A of FIG. 2. Some portions of underframe 12 have been omitted in FIG. 3 for clarity. As illustrated in FIG. 3, longitudinal beam 46 may be a generally I-shaped beam, having upper flange 82 (or upper plate 82), lower flange 84 (or lower plate 84), and web 86 (or center sill 86). Upper flange 82 and lower flange 84 may each extend along the longitudinal direction (e.g., +X or -X direction) for an entire length of longitudinal beam 46. Upper flange 82 and lower flange 84 may each also extend in the transverse direction (e.g., +Y or -Y direction). Upper flange 82 and lower flange 84 may be disposed generally parallel to each other. In some exemplary embodiments as illustrated in FIG. 3, upper flange 82 and lower flange 84 and may be disposed offset relative to each other in the transverse direction (e.g., +X or -X). Upper flange 82 may be spaced apart from lower flange 84 with web 86 extending between upper flange 82 and lower flange 84. Opposite ends of web 86 may be connected to upper flange 82 and lower flange 84. In some exemplary embodiments, upper flange 82, lower flange 84, and web 86 may be separate components that may be joined to each other. In other exemplary embodiments, upper flange 82, lower flange 84, and web 86 may be formed as an integrated structure for longitudinal beam 46. In some exemplary embodiments as illustrated in FIG. 3, web 86 may be disposed generally perpendicular to upper flange 82 and lower flange 84.

[0034] Longitudinal beam 46 may include outer web 98 (or outer sill 98). Outer web 88 may extend from upper flange 82 towards lower flange 84. In some exemplary embodiments as illustrated in FIG. 3, outer web 88 may be disposed generally parallel to web 86 and generally perpendicular to upper flange 82.

[0035]As also illustrated in FIG. 3, longitudinal beam 48 may be a generally I-shaped beam, having upper flange 92 (or upper plate 92), lower flange 94 (or lower plate 94), and web 96 (or center sill 96). Upper flange 92 and lower flange 94 may each extend along the longitudinal direction (e.g., +X or -X direction) for an entire length of longitudinal beam 48. Upper flange 92 and lower flange 94 may each also extend in the transverse direction (e.g., +Y or -Y direction). Upper flange 92 and lower flange 94 may be disposed generally parallel to each other. In some exemplary embodiments as illustrated in FIG. 3, upper flange 92 and lower flange 94 and may be disposed offset relative to each other in the transverse direction (e.g., +Y or -Y direction). Upper flange 92 may be spaced apart from lower flange 94 with web 96 extending between upper flange 92 and lower flange 94. Opposite ends of web 96 may be connected to upper flange 92 and lower flange 94. In some exemplary embodiments, upper flange 92, lower flange 94, and web 96 may be separate components that may be joined to each other. In other exemplary embodiments, upper flange 92, lower flange 94, and web 96 may be formed as an integrated structure for longitudinal beam 48. In some exemplary embodiments as illustrated in FIG. 3, web 96 may be disposed generally perpendicular to upper flange 92 and lower flange 94.

[0036]In some exemplary embodiments, longitudinal beam 48 may also include outer web 98 (or outer sill 98). Outer web 98 may extend from upper flange 92 towards lower flange 94. In some exemplary embodiments as illustrated in FIG. 3, outer web 98 may be disposed generally parallel to web 96 and generally perpendicular to upper flange 92.

[0037] In some exemplary embodiments, a thickness of upper flanges 82, 92 may be about 17 mm to 21 mm. Compare this with a thickness of about 35 mm to 38 mm for similar flanges on conventional underframes. In some exemplary embodiments, a thickness of lower flanges 84, 94 may be about 35 mm to 40 mm. Compare this with a thickness of about 60 mm to 65 mm for similar flanges on conventional underframes. In some exemplary embodiments, a thickness of webs 86, 96 may be about 17 mm to 21 mm. Compare this with a thickness of about 23 mm to 27 mm for similar webs on conventional underframes.

[0038]As further illustrated in FIG. 3, underframe 12 may include bracket 102 (or left bracket 102) and bracket 104 (or right bracket 104). Left bracket 102 may extend between upper flange 82 and lower flange 84 of longitudinal beam 46. Left bracket 102 may be attached to one or more of upper flange 82, lower flange 84, web 86, and/or outer web 88. Left bracket 102 may help provide additional rigidity to longitudinal beam 46 by allowing a weight of machine components 26 to be supported by longitudinal beam 46, while minimizing the likelihood of deflection or bending of upper flange 82, lower flange 84, and/or web 86. Likewise, right bracket 104 may extend between upper flange 92 and lower flange 94 of longitudinal beam 48. Right bracket 104 may be attached to one or more of upper flange 92, lower flange 94, web 96, and/or outer web 98. Right bracket 104 may help provide additional rigidity to longitudinal beam 48 by allowing a weight of machine components 26 to be supported by longitudinal beam 48, while minimizing the likelihood of deflection or bending of upper flange 92, lower flange 94, and/or web 96.

[0039] With reference to FIG. 3, upper flange 82 and lower flange 84 of longitudinal beam 46 and may be disposed offset relative to each other in the transverse direction (e.g., +Y or -Y direction). For example, as illustrated in FIG. 3, a smaller width of upper flange 82 of longitudinal beam 46 may extend in a direction towards longitudinal beam 48, whereas a larger width of lower flange 84 of longitudinal beam 46 may extend in a direction towards longitudinal beam 48. Similarly, upper flange 92 and lower flange 94 of longitudinal beam 48 may be disposed offset relative to each other in the transverse direction (e.g., +Y or -Y direction). For example, as illustrated in FIG. 3, a smaller width of upper flange 92 of longitudinal beam 48 may extend in a direction towards longitudinal beam 46, whereas a larger width of lower flange 94 of longitudinal beam 48 may extend in a direction towards longitudinal beam 46. In other words, a distance between upper flanges 82 and 92 in the transverse direction (e.g., +Y or -Y direction) may be greater than a distance between lower flanges 84 and 94 in the transverse direction (e.g., +Y or -Y direction).

[0040]FIG. 4 depicts a magnified partial view of the cross-section of FIG. 3, illustrating longitudinal beam 46. As illustrated in FIG. 4, upper flange 82 may include upper shelf 110 (or outer portion 110) and upper projection 112 (or inner portion 112). Upper shelf 110 may extend outward (e.g., away from longitudinal beam 48, see FIG. 3) from web 86 to upper shelf end 114 in a transverse direction (e.g., -Y direction). Upper projection 112 may extend inward (e.g., toward longitudinal beam 48, see FIG. 3) from web 86 to upper projection end 116 in a transverse direction (e.g., +Y direction). Thus, upper flange 82 may be asymmetrically arranged relative to web 86 such that a width of upper shelf 110 may be greater a width of upper projection 112. Outer web 88 may extend from upper shelf end 114 towards lower flange 84. In some exemplary embodiments as illustrated in FIG. 4, outer web 88 may take the form of a thin plate.

[0041]As further illustrated in FIG. 4, lower flange 84 may include lower projection 118 (or outer portion 118) and lower shelf 120 (or inner portion 120). Lower projection 118 may extend outward (e.g., away from longitudinal beam 48, see FIG. 3) from web 86 to lower projection end 122 in a transverse direction (e.g., -Y direction). Lower shelf 120 may extend inward (e.g., toward longitudinal beam 48, see FIG. 3) from web 86 to lower shelf end 124 in a transverse direction (e.g., +Y direction). Thus, lower flange 84 may be asymmetrically arranged relative to web 86 such that a width of lower shelf 120 may be greater a width of lower projection 118. As also seen in FIG. 4, upper shelf 110 and lower shelf 120 may be disposed on opposite sides of web 86, and similarly, upper projection 112, and lower projection 118 may be disposed on opposite sides of web 86.

[0042]Further referring to FIG. 4, left bracket 102 may be disposed between upper shelf 110 (of upper flange 82), lower projection 118 (of lower flange 84), and web 86. Left bracket 102 may be a generally inverted L-shaped bracket, including vertical leg 132 (or first leg 132) and horizontal leg 134 (or second leg 134). Vertical leg 132 may extend generally perpendicular to upper flange 82 and lower flange 84 and generally parallel to web 86. Horizontal leg 134 of left bracket 102 may extend generally parallel to upper flange 82 and lower flange 84 and generally perpendicular to web 86. Vertical leg 132 may extend from lower projection 118 to upper shelf 110. Horizontal leg 134 may be disposed nearer to upper flange 82 relative to lower flange 84 and may extend from vertical leg 132 outward (e.g., away from longitudinal beam 48, see FIG. 3) toward outer web 88. Left bracket 102 may include right edge 140 that may be attached to web 86 and top edge 146 that may be attached to upper shelf 110. In some exemplary embodiments, bottom edge 144 of vertical leg 132 may be attached to lower projection 118 and left edge 150 of horizontal leg 134 may be attached to outer web 88. A width of vertical leg 132 adjacent to lower flange 84 may be generally smaller than a width of lower projection 118. Similarly, as illustrated in FIG. 4, a height of horizontal leg 134 adjacent to outer web 88 may be generally smaller than a height of outer web 88. In some exemplary embodiments, some or all left brackets 102 may additionally or alternatively be C-shaped and may have an additional leg extending from web 86 towards outer web 88, and the additional leg may be attached to lower projection 118.

[0043]FIG. 5 depicts a magnified partial view of the cross-section of FIG. 3, illustrating longitudinal beam 48. As illustrated in FIG. 5, upper flange 92 may include upper shelf 160 (or outer portion 160) and upper projection 162 (or inner portion 162). Upper shelf 160 may extend outward (e.g., away from longitudinal beam 46, see FIG. 3) from web 96 to upper shelf end 164 in a transverse direction (e.g., +Y direction). Upper projection 162 may extend inward (e.g., toward longitudinal beam 46, see FIG. 3) from web 86 to upper projection end 166 in a transverse direction (e.g., -Y direction). Thus, upper flange 92 may be asymmetrically arranged relative to web 96 such that a width of upper shelf 160 may be greater a width of upper projection 162. Outer web 98 may extend from upper shelf end 164 towards lower flange 94. In some exemplary embodiments as illustrated in FIG. 5, outer web 98 may take the form of a thin plate.

[0044]As further illustrated in FIG. 5, lower flange 94 may include lower projection 168 (or outer portion 168) and lower shelf 170 (or inner portion 170). Lower projection 168 may extend outward (e.g., away from longitudinal beam 46, see FIG. 3) from web 96 to lower projection end 172 in a transverse direction (e.g., +Y direction). Lower shelf 170 may extend inward (e.g., toward longitudinal beam 46, see FIG. 3) from web 86 to lower shelf end 174 in a transverse direction (e.g., -Y direction). Thus, lower flange 94 may be asymmetrically arranged relative to web 96 such that a width of lower shelf 170 may be greater a width of lower projection 168. As also seen in FIG. 5, upper shelf 160 and lower shelf 170 may be disposed on opposite sides of web 96, and similarly, upper projection 162, and lower projection 168 may be disposed on opposite sides of web 96.

[0045]Further referring to FIG. 5, right bracket 104 may be disposed between upper shelf 160 (of upper flange 92), lower projection 168 (of lower flange 94), and web 96. Right bracket 104 may be a generally inverted L-shaped bracket, including vertical leg 182 (or first leg 182) and horizontal leg 184 (or second leg 184). Vertical leg 182 may extend generally perpendicular to upper flange 92 and lower flange 94 and generally parallel to web 96. Horizontal leg 184 of right bracket 104 may extend generally parallel to upper flange 92 and lower flange 94 and generally perpendicular to web 96. Vertical leg 182 may extend from lower projection 168 to upper shelf 160. Horizontal leg 184 may be disposed nearer to upper flange 92 relative to lower flange 94 and may extend from vertical leg 182 outward (e.g., away from longitudinal beam 46, see FIG. 3) toward outer web 98. Right bracket 104 may include left edge 190 that may be attached to web 96 and top edge 196 that may be attached to upper shelf 160. In some exemplary embodiments, bottom edge 194 of vertical leg 182 may be attached to lower projection 168 and right edge 200 of horizontal leg 184 may be attached to outer web 98. A width of vertical leg 182 adjacent to lower flange 94 may be generally smaller than a width of lower projection 168. Similarly, as illustrated in FIG. 5, a height of horizontal leg 184 adjacent to outer web 98 may be generally smaller than a height of outer web 98.

[0046]As also illustrated in FIG. 5, horizontal leg 184 of right bracket 104 may include lower edge 198 disposed opposite to upper edge 196 and upper flange 92. Lower edge 198 may include relief 202 (or cutout 202) in the form of a curved portion that may extend from lower edge 198 toward upper edge 196 and upper flange 92. Relief 202 may help accommodate one or more ducts, pipes, or wiring in the space between upper flange 92 and lower flange 94. Although relief 202 has been illustrated on horizontal leg 184, in some exemplary embodiments, such relief may also be present additionally or alternatively on vertical leg 182. Similarly, relief 202 may additionally or alternatively be present on one or both of vertical leg 132 (see FIG. 4) and/or horizontal leg 134 (see FIG. 4) of left bracket 102 (see FIG. 4). It is also contemplated that relief 202 may be present on vertical legs 132, 182 and/or horizontal legs 134, 184 of some or all of left brackets 102 and/or right brackets 104, respectively. In some exemplary embodiments, some or all right brackets 104 may additionally or alternatively be C-shaped and may have an additional leg extending from web 96 towards outer web 98, and the additional leg may be attached to lower projection 168

[0047]With reference to FIGS. 3-5, cross beam 56 may extend from first end portion 106 to second end portion 108. First end portion 106 of cross beam 56 may be attached to upper projection 112 of upper flange 82 and/or to web 86 of longitudinal beam 46, whereas second end portion 108 of cross beam 56 may be attached to upper projection 162 of upper flange 92 and/or to web 96 of longitudinal beam 48.

[0048]FIG. 6 illustrates a partial perspective view showing the cross-section of underframe 12 taken along line A-A of FIG. 2. As illustrated in FIG. 6, underframe 12 may include cross beam 56A extending between and connected to longitudinal beams 46 and 48. Similarly cross beam 56B may extend between and may be connected to longitudinal beams 46 and 48. As illustrated in FIG. 6, cross beam 56A may be located at a position 106A relative to the longitudinal direction (e.g., +X or -X direction) and cross beam 56B may be located at a position 106B that may be spaced apart in the longitudinal direction from position 106A. As also illustrated in FIG. 6, left brackets 102A and 102B may be attached to longitudinal beam 46. Left brackets 102A and 102B may be spaced apart from each other in the longitudinal direction (e.g., +X or -X direction). Similarly, right brackets 104A and 104B may be attached to longitudinal beam 46. Right brackets 104A and 104B may be spaced apart from each other in the longitudinal direction (e.g., +X or -X direction). Left brackets 102A and 102B may be positioned in transverse alignment with cross beams 56A and 56B, respectively. Similarly, right brackets 104A and 104B may be positioned in transverse alignment with cross beams 56A and 56B, respectively. Thus, left bracket 102A, right bracket 104A, and cross beam 56A may be aligned along a common transverse axis (e.g., axis extending in the +Y or -Y direction) and may be positioned at the same position 106A. Similarly, left bracket 102B, right bracket 104B, and cross beam 56B may be aligned along a common transverse axis (e.g., axis extending in the +Y or -Y direction) and may be positioned at the same position 106B. Positioning cross beams 56 (e.g., 56A, 56B, etc.), left brackets 102 (e.g., 102A, 102B, etc.), and right brackets 104 (e.g., 104A, 104B, etc.) may provide sufficient rigidity to underframe 12 to support a weight of machine components 26 when machine 10 is at rest or when machine 10 is in motion without causing undue deflections and distortions of underframe 12.

[0049]FIG. 7 illustrates a perspective view of an exemplary underframe 12 with machine components 26 disposed on underframe 12. For example, as illustrated in FIG. 7, a plurality of battery modules 28 may be disposed adjacent to each other on underframe 12 for machine 10 powered by a hybrid or electric engine. In one exemplary embodiment as illustrated in FIG. 7, a first plurality of battery modules 28A (e.g., 28A1, 28A2, . . . 28AN) may be positioned adjacent to each other on longitudinal beam 46, and a second plurality of battery modules 28B (e.g., 28B1, 28B2, . . . 28BN) may be positioned adjacent to each other on longitudinal beam 48. Battery modules 28A and 28B may be similar to battery modules 28. As also shown in FIG. 7, the second plurality of battery modules 28B may be arranged so that they are spaced apart from the first plurality of battery modules 28A by a gap 206 in the transverse direction (e.g., +Y or -Y direction). A longitudinal walkway may be defined in gap 206 to allow an operator to travel from operator cabin 22 disposed adjacent to front end 42 to storage compartment 24 disposed adjacent to rear end 44.

[0050]As further illustrated in FIG. 7, a plurality of covers 208 may cover gap 206 (only one cover 208 is shown in FIG. 7). Each cover 208 may be disposed over a battery module 28A and an oppositely located battery module 28B. For example, as shown in FIG. 7, cover 208 may be disposed over battery module 28A4 and battery module 28B4. In some exemplary embodiments, cover 208 may be attached to battery modules 28A4 and 28B4 via one or more fasteners. For example, one or more brackets (not shown) may be disposed at or adjacent to attachment locations 210, 212, 214, and 216 of cover 208. Attachment locations 210, 212, 214, and 216 of cover 208 may be connected to attachment locations at or adjacent to corners 220, 222, 224, and 226, respectively, of battery modules 28A4 and 28B4 via one or more fasteners. In one exemplary embodiment as illustrated in FIG. 7, attachment locations at or adjacent to corners 220 and 224 may be associated with inner portions (e.g., facing gap 206) of battery module 28A4. Likewise, attachment locations at or adjacent to corners 222 and 226 may be associated with inner portions (e.g., facing gap 206) of battery module 28B4. Thus, covers 208 may help to connect battery module 28A4 with its oppositely located battery module 28B4. Such a connection may help reduce the number of degrees of freedom of movement associated with each of battery modules 28A and 28B. Although cover 208 has been described as being connected only to the inner portions of battery modules 28A and 28B, it should be understood that cover 208 may be connected to any other portions of battery modules 28A and/or 28B.

[0051]Additionally or alternatively, in some exemplary embodiments, adjacently located battery modules 28A may be connected to each other and adjacently located battery modules 28B may be connected to each other. For example, as illustrated in FIG. 7, an attachment location at or adjacent to inner corner 240 of battery module 28A6 may be connected to an attachment location at or adjacent to inner corner 242 of battery module 28A7 via one or more brackets and/or one or more fasteners. Similarly, as illustrated in FIG. 7, an attachment location at or adjacent to inner corner 250 of battery module 28B8 may be connected to an attachment location at or adjacent to inner corner 252 of battery module 28B9 via one or more brackets and/or one or more fasteners. It is contemplated that in some exemplary embodiments, battery modules 28A (e.g., 28A1, 28A2, 28A3 . . . 28AN) may be connected to adjacently located battery modules 28A at one or more locations. It is also contemplated that in some exemplary embodiments, battery modules 28B (e.g., 28B1, 28B2, 28B3 . . . 28BN) may be connected to adjacently located battery modules 28B at one or more attachment locations. Connecting adjacently located battery modules 28A with each other and adjacently located battery modules 28B with each other may also help reduce the number of degrees of freedom of the entire battery module assembly, making the assembly sturdier, more rigid, and less likely to suffer excessive displacement in any direction (e.g., in any of the X, Y, or Z directions).

[0052]In some embodiments, a battery module 28A (e.g., 28A1) located adjacent to operator cabin 22 may additionally or alternatively be connected to operator cabin 22 via a bracket and one or more fasteners. Likewise, a battery module 28B (e.g., 28B1) located adjacent to operator cabin 22 may additionally or alternatively be connected to operator cabin 22 via a bracket and one or more fasteners. For example, a bracket and one or more fasteners may be used to connect an attachment location at or adjacent to outer corner 270 of battery module 28A1 with operator cabin 22. Similarly, for example, a bracket and one or more fasteners may be used to connect an attachmet location at or adjacent to outer corner 272 of battery module 28B1 with operator cabin 22. Moreover the brackets used to connect battery modules 28A1 or 28B1 to operator cabin 22 may allow for relative movement between operator cabin 22 and battery modules 28A4 or 28B4 along the longitudinal direction (e.g., along the +X or -X direction). In some exemplary embodiments, battery modules 28AN and 28BN located adjacent to storage compartment 24 may not be connected to storage compartment 24. In other exemplary embodiments, battery modules 28AN and 28BN located adjacent to storage compartment 24 may also be connected to storage compartment 24 using one or more brackets and/or fasteners in the same manner as described above for the connection between battery modules 28A1 and 28B1 with operator cabin 22.

[0053] As also illustrated in FIG. 7, each of battery modules 28A or 28B may be partially located on beam 46 or 48, respectively, and partially supported by one or more cross beams 56. In some exemplary embodiments, a number of cross beams 56 may be determined as a number of battery modules 28A divided by 2. It should be understood, however, that any number of cross beams 56 may be used to construct underframe 12. In some exemplary embodiments, a ratio of a width of underframe 12 (e.g., in the Y direction) to a length of cross beam 56 (e.g., in the Y direction) may be about 1.5 to 3.0. In some exemplary embodiments, a ratio of a

[0054]FIG. 8 illustrates a magnified partial view of underframe 12 with only one battery module 28B positioned on underframe 12 to illustrate this characteristic. As illustrated in FIG. 8, beams 46 and 48, or more particularly, upper flanges 82 and 92, respectively, of beams 46 and 48 may include pads 282. In one exemplary embodiment as illustrated in FIG. 8, pads 282 may be disposed towards an outer periphery (e.g., nearer to upper shelf ends 114, 164, respectively) of upper flanges 82 and 92. It is contemplated, however, that pads 282 may be disposed anywhere on upper flanges 82 and 92. Similarly, pads 284 may be disposed on wings 58 projecting in the longitudinal direction from the one or more cross beams 56. As further illustrated in FIG. 7, battery module 28B may be attached to pads 282 and 284, using fasteners (not shown). Thus, a weight of battery module 28B may be supported by both upper flanges 82 and 92 of beams 46 and 48, respectively, and by the one or more cross beams 56 to which battery module 28B is attached. It should be understood that battery module 28B illustrated in FIG. 8 is exemplary and other components (e.g., engines, pumps, auxiliary equipment) may similarly be attached to and supported by upper flanges 82 and 92 of beams 46 and 48, respectively, and by the one or more cross beams 56.

INDUSTRIAL APPLICABILITY

[0055]The disclosed underframe 12 provides a lightweight or reduced weight underframe for machine 10 such as a locomotive. In some exemplary embodiments, a weight of the disclosed underframe 12 may be about 35% to 40% lighter than a conventional underframe used on a typical locomotive. The disclosed underframe 12 may include upper flanges 82, 92, lower flanges 84, 94, center sills 86, 96, and/or outer sills 88, 98, some or all of which may have thicknesses less than thicknesses of similar conventional components, thereby reducing a weight of the underframe. Furthermore, the disclosed underframe 12 may employ cross-beams 56 to connect beams 46 and 48, instead of using conventional cross plates (similar to cross plates 60), further reducing the weight of underframe 12.

[0056]Underframe 12 may also employ a plurality of left brackets 102 disposed between upper flange 82 and lower flange 84 and/or a plurality of right brackets 104 disposed between upper flange 92 and lower flange 94 to provide additional rigidity to underframe 12. The increased rigidity may help to reduce stresses generated in and/or deflections of upper flange 82, lower flange 84, and/or web 86 of beam 46 due to the weight of machine components 26. Likewise, the increased rigidity may also help to reduce stress generated in and/or or deflection of upper flange 92, lower flange 94, and/or web 96 of beam 48 due to the weight of machine components 26. Further, by placing the left and right brackets 102, 104, and cross beams 56 in transverse alignment, underframe 12 may help support a weight of machine components 26 without causing excessive bending of upper flanges 82, 92, of beams 46, 48. By using cross beams 56 and left and right brackets 102, 104, underframe 12 may provide sufficient rigidity to support machine components 26, without the need for thick plates connecting beams 46 and 48 as is done on conventional underframes.

[0057] The reduced weight of underframe 12 may provide an additional advantages. For example, the reduced weight of underframe 12 may reduce the overall weight of machine 10, which in turn helps improve fuel efficiency. The reduction in the overall weight of machine 10 also reduces the fraction of the overall weight that must be supported by each axle 18, and may help to minimize the number of axles 18 required to support machine 10 on railroad tracks 16. Reducing the load per axle may reduce the wear and tear of the axle and associated components, thereby decreasing the maintenance expenses associated with machine 10 and may help extend the usable life of machine 10. Similarly, reducing the number of axles 18 required to support the weight of machine 10 decreases the number of components requiring repair or replacement, further lowering the expenses associated with operating machine 10.

[0058]Machines 10 such as locomotives may be required to travel at high speeds (e.g., 70 to 80 miles per hour) while negotiating curves having radii ranging between about 200 to 300 feet. As the locomotive travels around the curve at high speed, machine components 26 disposed on underframe 12 exert a turning moment on the locomotive, that may tend to displace machine components 26 and tilt the locomotive towards the center of the curve. Because of the rigidity provided by cross beams 56 and left and right brackets 102, 104, the amount of bending in upper flanges 82, 92 of beams 46, 48, respectively, may be minimized. This in turn may help improve the stability of machine 10 by prevent machine components 26 from exerting a large enough turning moment capable of overturning or derailing machine 10. Thus, underframe 12 of the present disclosure may help provide a reduced weight that in turn may allow for safe and efficient operation of machine 10.

[0059] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed underframe. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed underframe. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.