Development and justification of technical solutions for the design of a long-base flat car for the transportation of high-capacity containers

Rahimov, Rustam; Zafarov, Diyor; Khurmatov, Yakhyo · 2026 · Crossref

DOI: 10.1038/s41598-026-40185-3

archive: archived pipeline: cataloged verified

Get this paper ↗ (DOI — opens at the source; we link to it, we don't host it)

Summary

This study addresses the need to improve the efficiency of container transportation by developing and justifying technical solutions for a long-base flat car. The research is motivated by the limitations of traditional flat cars in the Republic of Uzbekistan, which typically transport only one 40-foot or two 20-foot containers, leaving loading length underutilized and reducing overall transport efficiency. The authors aim to design an improved long-base flat car that maximizes load capacity, reduces tare weight, and ensures structural reliability under modern operating conditions. The methodology involved a comparative analysis of existing flat car models to select a prototype, followed by theoretical and experimental validation. The 13-644 model was chosen as the baseline due to its compatibility with 1520 mm gauge railways and existing production capabilities in Uzbekistan. The authors optimized the load-bearing structure by analyzing various welded I-beam configurations using finite element method (FEM) simulations in SolidWorks and ANSYS Workbench. They evaluated beams of different heights and cross-sections made of 09G2S low-alloy steel under a vertical load of 17.5 tons. The optimal beam design (700 mm height) was selected based on criteria of minimum weight and maximum safety margin. Subsequent FEM analysis assessed the stress-strain state of the full car frame under two loading schemes (four 20-foot or two 40-foot containers) and various dynamic modes, including collision, braking, and acceleration. These numerical results were validated through experimental static and running tests using the strain gauge method. The results demonstrate that the optimized 700 mm I-beam design reduces the car’s tare weight by 1 ton, thereby increasing its load capacity by the same amount, while maintaining a safety factor of 1.91. The FEM analysis revealed that loading with four 20-foot containers generates higher maximum equivalent stresses than loading with two 40-foot containers, due to more complex load distribution and smaller inter-container distances. However, all calculated stresses remained within permissible limits for the steel used. Experimental data obtained via strain gauges showed satisfactory correspondence with the numerical modeling results, confirming the accuracy of the theoretical predictions and the structural soundness of the design. The significance of this work lies in the successful development of a competitive long-base flat car design that enhances the efficiency of container transportation. The improved technical and operational characteristics, including reduced tare weight and increased durability, contribute to lower transportation costs per unit of cargo. The study concludes that the proposed design is ready for industrial implementation, noting that car-building enterprises in Uzbekistan have already established production of these promising long-base flat cars. This advancement supports the modernization of railway infrastructure and improves the competitiveness of freight transport in the region.

Provenance

The full processing record for this entry. Every stage of this paper's journey through the pipeline is logged — what ran, with which tool and model, how many attempts it took, and when it last completed.

Summary generated by qwen3.6-27b-prismaquant on 2026-06-26; verification: verified.

Topics

Ranked by relevance to this paper. Hover a topic for its definition.

• truck driver fatigue