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

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.