EP3131801A1

EP3131801A1 - Suspension module for a rail vehicle

Info

Publication number: EP3131801A1
Application number: EP15723735.5A
Authority: EP
Inventors: Wayne Jamieson; William Alan Aitken
Original assignee: Wabtec Rail Scotland Ltd
Current assignee: Wabtec Rail Scotland Ltd
Priority date: 2014-04-16
Filing date: 2015-04-16
Publication date: 2017-02-22
Also published as: WO2015159085A1

Abstract

A suspension module (101, 201) for supporting an axle (22) and wheelset (24) on a railcar bogie (14) includes a frame (104, 204) configured to be connected to attachment points (30) defined on the railcar bogie; an axle box (108, 208) configured to engage the axle; at least one coil spring (102, 202) disposed between the axle box and the frame and configured to bias the railcar bogie upwardly with respect to the axle; at least one wedge plate (112, 212), the at least one wedge plate having at least one face (112a, 112b, 212a, 212b); and at least one wear plate (114, 214) disposed on the frame and in frictional contact with the at least one face of the wedge plate.

Description

SUSPENSION MODULE FOR A RAIL VEHICLE

BACKGROUND OF THE INVENTION

Field of the Invention

[001] The present invention relates generally to suspension modules and, in particular, to suspension modules and a method for converting a leaf spring suspension system of a rail vehicle to a coil spring suspension system.

Description of Related Art

[002] Many types of rail vehicles are known, including box cars and hopper cars, for transporting various materials on a railway. These types of rail vehicles generally include a frame that is supported by two or more bogies. Each bogie has a pair of axles having a wheelset rotatably supported thereon and a suspension system. In certain applications, the suspension system has a plurality of leaf springs. A leaf spring typically takes the form of a slender arc-shaped length of spring steel having a substantially rectangular cross section. In applications requiring heavy load capacity, a plurality of leaf springs of varying lengths is typically stacked on top of each other in several layers, often with progressively shorter leaves. The center portion of the leaf spring supports the axle, while terminal ends of the leaf spring are attached to the bogie. In certain embodiments, hydraulic dampers can be added to dampen the action of the leaf springs.

[003] While a leaf spring suspension system provides high load capacity, it is associated with a number of disadvantages. The leaf spring suspension system does not provide good riding comfort because of inter-leaf friction between the individual leaf springs. This is a very harsh and unreliable method of damping. Furthermore, rail vehicles equipped with leaf spring suspension systems are often not suitable for high-speed operation. Due to their low speed, railway network operators cannot increase traffic on the railway network.

SUMMARY OF THE INVENTION

[004] Generally, provided is an improved suspension module for a rail vehicle that addresses certain drawbacks and deficiencies in existing suspension systems and arrangements for rail cars and similar vehicles.

[005] In view of the disadvantages of rail vehicles equipped with leaf spring suspension systems, it is desirable to provide a new approach for increasing the speed and comfort of the rail vehicles, while maintaining their load capacity. Rather than replacing the leaf spring suspended rail vehicles with modern rail vehicles having coil spring suspension, in one preferred and non-limiting embodiment, the presently disclosed system and arrangement utilizes a bogie frame of an existing leaf spring suspended rail vehicle and incorporates a suspension module having coil springs. In accordance with one preferred and non-limiting embodiment of the present disclosure, a bogie for supporting a body of a rail vehicle may include a bogie frame having a pair of attachment points and at least two wheelsets, each wheelset including an axle and two wheels rotatably disposed on the axle. The bogie may further include a suspension module operatively connected to the attachment points on the bogie frame for supporting the at least two wheelsets on the bogie frame. The suspension module may include at least one load- supporting coil spring adapted to bias the body upwardly, at least one wedge plate having a first substantially vertical face and a second substantially sloped face, and at least one wear plate in frictional contact with at least the second substantially sloped face.

[006] In accordance with another preferred and non-limiting embodiment, a method for converting a leaf spring suspension system of a rail vehicle to a coil spring suspension system may include removing the leaf spring suspension system from a bogie supporting a body of the rail vehicle by uncoupling the leaf spring suspension system from suspension attachment points provided on the bogie. Additionally, the method may include installing a coil spring suspension system having a suspension module to the bogie. The suspension module may be operatively connected to the bogie by connecting the suspension module to the suspension attachment points.

[007] According to one particular embodiment of the present disclosure, a suspension module for supporting an axle and wheelset on a railcar bogie is provided. The suspension module includes a frame configured to be connected to attachment points defined on the railcar bogie; an axle box configured to engage the axle; at least one coil spring disposed between the axle box and the frame and configured to bias the railcar bogie upwardly with respect to the axle; at least one wedge plate, the at least one wedge plate having at least one face; and at least one wear plate disposed on the frame and in frictional contact with the at least one face of the wedge plate. The frame is configured to be connected to the railcar bogie at opposing longitudinal ends thereof. The suspension module may also include a traction link connected between the axle box and the railcar bogie, and configured to restrict movement of at least the axle box with respect to the railcar bogie in a longitudinal direction. The at least one spring may include at least one set of concentric springs, which includes a tare spring and a laden spring. The at least one spring may include at least one spring disposed on a forward side of the axle box, at least one spring disposed on a rearward side of the axle box, and at least one spring disposed above the axle box. The at least one face of the at least one wedge plate includes at least one sloped face and at least one substantially vertical face. The at least one face of the at least one wedge plate may be lined with a composite material. The at least one wedge plate is disposed between the at least one spring and the at least one wear plate such that the at least one spring biases the at least one face of the at least one wedge plate into contact with the at least one wear plate.

[008] The suspension module may further include mounting plates configured to rigidly connect the frame to the railcar bogie at the attachment points. The axle box may be connected to the frame so as to be movable with respect to the frame in a longitudinal direction, a vertical direction, and a lateral direction. The at least one wedge plate may include at least two wedge plates and the at least one wear plate may include at least two wear plates, each of the at least two wear plates being in frictional contact with the at least one face of a respective one of the at least two wedge plates, and the respective wear plates and wedge plates being disposed on opposing forward and rearward sides of the axle box.

[009] Alternatively, the suspension module may further include swing links configured to movably connect the frame to the railcar bogie at the attachment points so as to allow the module to move longitudinally with respect to the railcar bogie. The axle box may be connected to the frame so as to be movable with respect to the frame in a vertical direction and a lateral direction, and so as to be fixed with respect to the frame in a longitudinal direction. The axle box may include a fixed composite face in frictional contact with a portion of the frame.

[0010] According to another particular embodiment of the present disclosure, a method of converting a leaf spring suspension system on a railcar bogie to a coil spring suspension system is provided. The railcar bogie includes a frame including at least one longitudinal member having a plurality of attachment points for the leaf spring suspension system defined thereon, an axle operatively connected to the frame, and at least one wheelset disposed on the axle. The method includes removing the leaf spring suspension system from the frame of the railcar bogie by uncoupling the leaf spring suspension system from the attachment points on the frame; providing at least one above-described suspension module; installing the at least one suspension module on the railcar bogie by connecting the frame of the suspension module to the attachment points on the at least one longitudinal member of the frame of the railcar bogie; and engaging the axle of the railcar bogie with the axle box of the suspension module. [0011] The installing step may include rigidly connecting the frame of the suspension module to the attachment points with mounting plates. The axle box of the suspension module may be movable with respect to the frame of the suspension module in a longitudinal direction, whereby the at least one wheelset is allowed to radially steer.

[0012] Alternatively, the installing step may include movably connecting the frame of the suspension module to the attachment points with swing links that allow the module to move in a longitudinal direction with respect to the railcar bogie. The axle box of the suspension module may be fixed with respect to the frame of the suspension module in the longitudinal direction, whereby the at least one wheelset is allowed to radially steer.

[0013] Further details and advantages of the various embodiments detailed herein will become clear upon reviewing the following detailed description of the preferred embodiments in conjunction with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a side view of a leaf spring suspension system in accordance with the prior art;

[0015] FIG. 2 is a side view of a first embodiment of a suspension module in accordance with the principles of the present disclosure; and

[0016] FIG. 3 is a side view of a second embodiment of a suspension module in accordance with the principles of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0017] For purposes of the description hereinafter, spatial orientation terms, as used, shall relate to the referenced embodiment as it is oriented in the accompanying drawing figures or otherwise described in the following detailed description. However, it is to be understood that the embodiments described hereinafter may assume many alternative variations and configurations. It is also to be understood that the specific components, devices, and features illustrated in the accompanying drawing figures and described herein are simply exemplary and should not be considered as limiting.

[0018] The term "longitudinal direction" as used herein refers to the direction extending along a length of a railcar parallel to the direction of the rail upon which the railcar travels, i.e., the direction extending from the forward end of the railcar to the rearward end of the railcar. The term "lateral direction" as used herein refers to the direction extending along a width of the railcar perpendicular to the direction of the rail upon which the railcar travels, i.e., the direction extending from the left side of the railcar to the right side of the railcar. The term "vertical direction" as used herein refers to the direction extending vertically from the rail upon which the railcar travels, i.e., the direction extending from the top of the railcar to the bottom of the railcar.

[0019] With reference to FIG. 1, a portion of a rail vehicle 10 including an existing bogie arrangement is illustrated. The rail vehicle 10 includes a body 12 supported on a pair of bogies 14 (only one bogie shown in FIG. 1). The bogies 14 are separated longitudinally from each other in a fore and aft direction along a rail 16. The bogie 14 has a frame 18 including a pair of longitudinal beams 20 (only one beam shown in FIG. 1) extending substantially parallel to the rail 16 and one or more cross beams (not shown) extending substantially perpendicular to the rail 16. A pair of axles 22, with each axle 22 having a wheelset 24 (only one axle 22 and wheelset 24 shown in FIG. 1), extends in a lateral direction between the longitudinal beams 20 and is rotatably supported on the frame 18 of the bogie 14.

[0020] With continuing reference to FIG. 1, the bogie 14 includes a suspension system 26 for supporting the axles 22, such that the axles 22 can be displaced in a vertical direction relative to the bogie frame 18. The suspension system 26 includes a leaf spring 28 provided on opposing ends of the axles 22 and extending in a direction of the longitudinal beams 20. The leaf spring 28 is substantially arc shaped in a longitudinal direction and has a substantially rectangular cross section. The leaf spring 28 is formed from a plurality of leaf spring elements of varying lengths. The leaf spring elements are stacked on top of each other in several layers. The center portion of the leaf spring 28 supports the axle 22, while terminal ends of the leaf spring 28 are attached to the bogie frame 18 at attachment points 30 via swing links 32. The leaf spring 28 has the function of a primary suspension for allowing the vertical movement of the axle 22 relative to the bogie frame 18.

[0021] With reference to FIG. 2, a suspension system 100 is shown in accordance with a preferred and non-limiting embodiment of the present disclosure. The suspension system 100 includes a suspension module 101 for supporting an axle 22 and wheelset 24 on a railcar bogie 14 (only a portion of which is illustrated in FIG. 2), such as the axle 22, wheelset 24, and railcar bogie 14 described above with reference to FIG. 1. The suspension module 101 is suitable for replacing the above-described suspension system 26 on such a railcar bogie 14, as is illustrated in FIG. 2. Similar to the suspension system 26 shown in FIG. 1, the suspension module 101 shown in FIG. 2 supports the axles 22 (only one axle shown in FIG. 2), such that the axles 22 can be displaced in a vertical direction relative to the bogie frame 18. However, rather than having leaf springs 28, such as the suspension system 26 shown in FIG. 1, the suspension module 101 of this embodiment includes a plurality of coil springs 102 configured to bias the railcar bogie 14 upwardly with respect to the axle 22.

[0022] The suspension module 101 also has a frame 104 configured to be connected to the bogie 14 at opposing longitudinal ends thereof with a pair of mounting plates 106 for attaching to the attachment points 30 defined on the bogie frame 18, which are the same attachment points 30 for the terminal ends of the leaf spring 28 in the prior art embodiment shown in FIG. 1. The mounting plates 106 are provided on the opposing longitudinal ends of the suspension module frame 104. The mounting plates 106 rigidly connect the suspension module frame 104 to the frame 18 of the railcar bogie 14.

[0023] The suspension module 101 also includes an axle box 108 configured to engage the axle 22 to support the axle 22 on the bogie 14. The axle box 108 is connected to the module frame 104 so as to be movable with respect to the module frame 104 in a longitudinal direction, in a vertical direction, and in a lateral direction with the movement of the axle 22. The longitudinal movement of the axle box 108 in the longitudinal direction allows for wheelset steering when the railcar is traveling on a curved track. The movement of the axle box 108 is controlled and restricted in the longitudinal direction by a traction link 110, which is connected to the axle box 108 at one end and to the bogie frame 18 at the other end. The traction link 110 provides stability by controlling the longitudinal movement of the wheelset 24 and preventing the wheelset 24 from becoming unstable. In another embodiment, a constant contact side-bearer (not shown) can be provided to further control the stability of the bogie 14.

[0024] As shown in FIG. 2, the suspension module 101 includes a plurality of coil springs 102 disposed between the axle box 108 and the module frame 104. In one embodiment, the coil springs 102 may include sets of springs 102a, 102b arranged in pairs disposed concentrically relative to each other. For example, one of the inner coil spring 102a and the outer coil spring 102b may be a tare coil spring configured for primarily controlling the suspension movement of an unloaded rail vehicle 10, while the other of the inner coil spring 102a and the outer coil spring 102b may be a laden coil spring configured for primarily controlling the suspension movement of a loaded rail vehicle 10. As shown in FIG. 2, at least one set of coil springs 102 is desirably provided on a forward side of the axle box 108 between a forwardly-extending flange 108a on the axle box 108 and module frame 104, on a rearward side between a rearwardly-extending flange 108b on the axle box 108 and the module frame 104, and between an upper portion of the axle box 108 and a central portion of the module frame 104. [0025] In addition to the sets of coil springs 102, the suspension module 101 further includes at least one wedge plate 112 having at least one face 112a, 112b in frictional contact with a corresponding at least one wear plate 114 disposed on the module frame 104. As shown in FIG. 2, the wedge plate 112 is disposed between a respective set of coil springs 102a, 102b and the respective wear plate 114 such that at least one or the other of the coil springs 102a, 102b biases the at least one face 112a, 112b of the wedge plate 112 into contact with the wear plate 114. As is also shown in FIG. 2, at least one wedge plate 112 and at least one wear plate 114 are provided on each of the opposing forward and rearward longitudinal sides of the axle box 108. The wedge plate 112 has a first generally vertical face 112a and a second generally sloped face 112b. The coil springs 102 bias the sloped face 112b of the wedge plate 112 against the wear plate 114. Multiple wedge plates 112 can be provided on opposite sides of the bogie 14 to allow the wheelsets 24 to steer radially while the railcar 10 travels on a curved track. The wedge plate 112 is lined with a composite material face to provide a consistent level of friction damping with low levels of stiction and good wear characteristics. In one preferred and non-limiting embodiment, the wear plate 114 is desirably made from cast iron to interface with the sloped face 112b of the wedge plate 112.

[0026] With reference to FIG. 3, a suspension system 200 is shown in accordance with another preferred and non-limiting embodiment of the present disclosure. The suspension system 200 includes a suspension module 201 for supporting an axle 22 and wheelset 24 on a railcar bogie 14 (only a portion of which is illustrated in FIG. 3), such as the axle 22, wheelset 24, and railcar bogie 14 described above with reference to FIG. 1. The suspension module 201 is suitable for replacing the above-described suspension system 26 on such a railcar bogie 14, as is illustrated in FIG. 3. Similar to the suspension system 26 shown in FIG. 1, the suspension module 201 shown in FIG. 3 supports the axles 22 (only one axle shown in FIG. 3), such that the axles 22 can be displaced in a vertical direction relative to the bogie frame 18. However, rather than having leaf springs 28, such as the suspension system 26 shown in FIG. 1, the suspension module 201 of this embodiment includes a plurality of coil springs 202 configured to bias the railcar bogie 14 upwardly with respect to the axle 22.

[0027] The suspension module 201 also has a frame 204 configured to be connected to the bogie 14 at opposing longitudinal ends thereof with a pair of swing links 206 for attaching to the attachment points 30 defined on the bogie frame 18, which are the same attachment points 30 for the terminal ends of the leaf spring 28 in the prior art embodiment shown in FIG. 1. The swing links 206 are provided on the opposing longitudinal ends of the suspension module frame 204. Rather than rigidly connecting the module frame 204 to the bogie frame 18 (such as the mounting plates 106 of the embodiment shown in FIG. 2), the swing links 206 movably connect the suspension module frame 204 to the frame 18 of the railcar bogie 14 so that the suspension module 201 is able to move longitudinally with respect to the rail car bogie 14. In this manner, the suspension module 201 in FIG. 3 is attached to the bogie frame 18 using the same attachment mechanism as is used in the prior art arrangement shown in FIG 1.

[0028] The suspension module 201 also includes an axle box 208 configured to engage the axle 22 to support the axle 22 on the bogie 14. The axle box 208 is connected to the module frame 204 so as to be movable with respect to the module frame 204 in a vertical direction and in a lateral direction with the movement of the axle 22. The axle box 208 is connected to the module frame 204 so as to be fixed with respect the frame 204 in the longitudinal direction. Instead, the entire suspension module 201, including the frame 204 and the axle box 208, is movable with respect to the bogie frame 18 in the longitudinal direction by way of the movable connection of the frame 204 to the attachment points 30 defined on the bogie frame 18 via the above-described swing links 206. The longitudinal movement of the axle box 208 in the longitudinal direction allows for wheelset steering when the railcar is traveling on a curved track. The movement of at least the axle box 208, and particularly the entire suspension module 201, is controlled and restricted in the longitudinal direction by a traction link 210, which is connected to the axle box 208 at one end and to the bogie frame 18 at the other end. The traction link 210 provides stability by controlling the longitudinal movement of the wheelset 24 and preventing the wheelset 24 from becoming unstable. In another embodiment, a constant contact side-bearer (not shown) can be provided to further control the stability of the bogie 14.

[0029] As shown in FIG. 3, the suspension module 201 includes a plurality of coil springs 202 disposed between the axle box 208 and the module frame 204. In one embodiment, the coil springs 202 may include sets of springs 202a, 202b arranged in pairs disposed concentrically relative to each other. For example, one of the inner coil spring 202a and the outer coil spring 202b may be a tare coil spring configured for primarily controlling the suspension movement of an unloaded rail vehicle 10, while the other of the inner coil spring 202a and the outer coil spring 202b may be a laden coil spring configured for primarily controlling the suspension movement of a loaded rail vehicle 10. As shown in FIG. 3, at least one set of coil springs 202 is desirably provided on a forward side of the axle box 208 between a forwardly-extending flange 208a on the axle box 208 and the module frame 204, on a rearward side between a rearwardly-extending flange 208b on the axle box 208 and the module frame 204, and between an upper portion of the axle box 208 and a central portion of the module frame 204.

[0030] In addition to the sets of coil springs 202, the suspension module 201 further includes a wedge plate 212 having at least one face 212a, 212b in frictional contact with a corresponding wear plate 214 disposed on the module frame 204. As shown in FIG. 3, the wedge plate 212 is disposed between a respective set of coil springs 202a, 202b and the wear plate 214 such that at least one or the other of the coil springs 202a, 202b biases the at least one face 212a, 212b of the wedge plate 212 into contact with the wear plate 214. As is also shown in FIG. 3, the suspension module 201 includes a single wedge plate 212 and wear plate 214 provided on a rearward longitudinal side of the axle box 208. The wedge plate 212 has a first generally vertical face 212a and a second generally sloped face 212b. The coil springs 202 bias the sloped face 212b of the wedge plate 212 against the wear plate 214. Multiple wedge plates 212 can be provided on opposite sides of the bogie 14 to allow the wheelsets 24 to steer radially while the railcar 10 travels on a curved track. The wedge plate 212 is lined with a composite material face to provide a consistent level of friction damping with low levels of stiction and good wear characteristics. In one preferred and non-limiting embodiment, the wear plate 214 is desirably made from cast iron to interface with the sloped face 212b of the wedge plate 212. Because the axle box 208 is constrained from longitudinal movement relative to the module frame 204, a fixed composite face 216 in frictional contact with a portion of the module frame 204 is provided on the forward longitudinal side of the axle box 208 opposite the wedge plate 212 and the wear plate 214 to provide friction damping between the axle box 208 and the module frame 204 in a vertical and lateral direction. It is to be appreciated that the position of the wedge plate 212 and wear plate 214 on the rearward longitudinal side of the axle box 208 may be switched with the position of the fixed composite face 216 on the forward longitudinal side of the axle box 208.

[0031] The suspension modules 101, 201 described above with reference to FIGS. 2 and 3 are configured so that they can each be manufactured as an assembly of castings and fabrications that would be assembled as a one-piece unit, ready for fitting to the railcar bogie 14. However, it is to be appreciated that the suspension modules 101, 201 may be manufactured and assembled on the railcar bogie 14 according to any method or technique known to be suitable by those having ordinary skill in the art.

[0032] Having described various preferred and non-limiting embodiments of the suspension modules 101, 201 with reference to FIGS. 2-3, a method for converting a leaf spring suspension system 26 on a railcar bogie 14 to a coil spring suspension system 100, 200 will now be described in accordance with a preferred and non-limiting embodiment of the present disclosure. The railcar bogie 14 includes a frame 18 having at least one longitudinal member 20 with a plurality of attachment points 30 for the leaf spring suspension system 26 defined thereon, an axle 22 operatively connected to the frame 18, and at least one wheelset 24 disposed on the axle 22. The method includes removing the leaf spring suspension system 26 from the frame 18 of the railcar bogie 14 by uncoupling the leaf spring suspension system 26 from the attachment points 30 on the frame 18; providing at least one suspension module 101, 201 of the type described above with reference to FIGS. 2 and 3; installing the at least one suspension module 101, 201 on the railcar bogie 14 by connecting the frame 104, 204 of the suspension module 101, 201 to the attachment points 30 on the at least one longitudinal member 20 of the frame 18 of the railcar bogie 14; and engaging the axle 22 of the railcar bogie 14 with the axle box 108, 208 of the suspension module 101, 201.

[0033] According to one alternative embodiment of the present disclosure, the installing step includes rigidly connecting the frame 104 of the suspension module 101 to the attachment points 30 with mounting plates 106. The axle box 108 of the suspension module 101 is movable with respect to the frame 104 of the suspension module 101 in a longitudinal direction, whereby the at least one wheelset 24 is allowed to radially steer.

[0034] According to another alternative embodiment of the present disclosure, the installing step includes movably connecting the frame 204 of the suspension module 201 to the attachment points 30 with swing links 206 that allow the module 201 to move in a longitudinal direction with respect to the railcar bogie 14. The axle box 208 of the suspension module 201 is fixed with respect to the frame 204 of the suspension module 201 in the longitudinal direction, whereby the at least one wheelset 24 is allowed to radially steer.

[0035] It is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the specification, are simply exemplary embodiments of the invention. Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope thereof. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims

CLAIMS:

1. A suspension module (101, 201) for supporting an axle (22) and wheelset (24) on a railcar bogie (14), the suspension module (101, 201) comprising:

a frame (104, 204) configured to be connected to attachment points (30) defined on the railcar bogie (14);

an axle box (108, 208) configured to engage the axle (22);

at least one coil spring (102, 202) disposed between the axle box (108, 208) and the frame (104, 204) and configured to bias the railcar bogie (14) upwardly with respect to the axle (22);

at least one wedge plate (112, 212), the at least one wedge plate (112, 212) having at least one face (112a, 112b, 212a, 212b); and

at least one wear plate (114, 214) disposed on the frame (104, 204) and in frictional contact with the at least one face (112a, 112b, 212a, 212b) of the at least one wedge plate (112, 212).

2. The suspension module (101) according to claim 1, further comprising mounting plates (106) configured to rigidly connect the frame (104) to the railcar bogie (14) at the attachment points (30).

3. The suspension module (201) according to claim 1, further comprising swing links (206) configured to movably connect the frame (204) to the railcar bogie (14) at the attachment points (30) so as to allow the module (201) to move longitudinally with respect to the railcar bogie (14).

4. The suspension module (101, 201) according to any of claims 1 to 3, wherein the frame (104, 204) is configured to be connected to the railcar bogie (14) at opposing longitudinal ends thereof.

5. The suspension module (101) according to any of claims 1, 2, and 4, wherein the axle box (108) is connected to the frame (104) so as to be movable with respect to the frame (104) in a longitudinal direction, a vertical direction, and a lateral direction.

6. The suspension module (201) according to any of claims 1, 3, and 4, wherein the axle box (208) is connected to the frame (204) so as to be movable with respect to the frame (204) in a vertical direction and a lateral direction and so as to be fixed with respect to the frame (204) in a longitudinal direction.

7. The suspension module (101, 201) according to any of claims 1 to 6, further comprising a traction link (110, 210) connected between the axle box (108, 208) and the railcar bogie (14) and configured to restrict movement of at least the axle box (108, 208) with respect to the railcar bogie (14) in a longitudinal direction.

8. The suspension module (101, 201) according to any of claims 1 to 7, wherein the at least one spring (102, 202) comprises at least one set of concentric springs (102a/102b, 202a/202b).

9. The suspension module (101, 201) according to claim 8, wherein the at least one set of concentric springs (102a/ 102b, 202a/202b) comprises a tare spring and a laden spring.

10. The suspension module (101, 201) according to any of claims 1 to 9, wherein the at least one spring (102, 202) comprises at least one spring (102, 202) disposed on a forward side of the axle box (108, 208), at least one spring (102, 202) disposed on a rearward side of the axle box (108, 208), and at least one spring (102, 202) disposed above the axle box (108, 208).

11. The suspension module (101, 201) according to any of claims 1 to 10, wherein the at least one face (112a, 112b, 212a, 212b) of the at least one wedge (112, 212) plate comprises at least one sloped face (112b, 212b) and at least one substantially vertical face (112a, 212a).

12. The suspension module (101, 201) according to any of claims 1 to 11, wherein the at least one face (112a, 112b, 212a, 212b) of the at least one wedge plate (112, 212) is lined with a composite material.

13. The suspension module (101, 201) according to any of claims 1 to 12, wherein the at least one wedge plate (112, 212) is disposed between the at least one spring (102, 202) and the at least one wear plate (114, 214) such that the at least one spring (102, 202) biases the at least one face (112a, 112b, 212a, 212b) of the at least one wedge plate (112, 212) into contact with the at least one wear plate (114, 214).

14. The suspension module (101) according to any of claims 1 to 13, wherein the at least one wedge plate (112) comprises at least two wedge plates (112) and the at least one wear plate (114) comprises at least two wear plates (114), each of the at least two wear plates (114) is in frictional contact with the at least one face (112a, 112b) of a respective one of the at least two wedge plates (112), and the respective wear plates (114) and wedge plates (112) are disposed on opposing forward and rearward sides of the axle box (108).

15. The suspension module (201) according to any of claims 1 to 13, wherein the axle box (208) comprises a fixed composite face (216) in frictional contact with a portion of the frame (204).

16. A method of converting a leaf spring suspension system (26) on a railcar bogie (14) to a coil spring suspension system (100, 200), the railcar bogie (14) comprising a frame (18) including at least one longitudinal member (20) having a plurality of attachment points (30) for the leaf spring suspension system (26) defined thereon, an axle (22) operatively connected to the frame (18), and at least one wheelset (24) disposed on the axle (22), the method comprising:

removing the leaf spring suspension system (26) from the frame (18) of the railcar bogie (14) by uncoupling the leaf spring suspension system (26) from the attachment points (30) on the frame (18);

providing at least one suspension module (101, 201) according to any of claims 1 to 15;

installing the at least one suspension module (101, 201) on the railcar bogie (14) by connecting the frame (104, 204) of the suspension module (101, 201) to the attachment points (30) on the at least one longitudinal member (20) of the frame (18) of the railcar bogie (14); and

engaging the axle (22) of the railcar bogie (14) with the axle box (108, 208) of the suspension module (101, 201).

17. The method according to claim 16, wherein the installing step includes rigidly connecting the frame (104) of the suspension module (101) to the attachment points (30) with mounting plates (106), and the axle box (108) of the suspension module (101) is movable with respect to the frame (104) of the suspension module (101) in a longitudinal direction, whereby the at least one wheelset (24) is allowed to radially steer.

18. The method according to claim 16, wherein the installing step includes movably connecting the frame (204) of the suspension module (201) to the attachment points (30) with swing links (206) that allow the module (201) to move in a longitudinal direction with respect to the railcar bogie (14), and the axle box (208) of the suspension module (201) is fixed with respect to the frame (204) of the suspension module (201) in the longitudinal direction, whereby the at least one wheelset (24) is allowed to radially steer.