EP3369638A1 - Wall module and a method for manufacturing components with wall modules for the shell of railway cars in rail vehicle construction in differential construction - Google Patents

Abstract

Summary: The invention relates to a wall module and a method for producing (manufacturing, pre and final assembly) of components (side wall, end wall, roof) with wall modules for the shell of car bodies in rail vehicle construction in differential construction with reduced manufacturing costs, improved dimensional stability, a comparable Structural rigidity for the outer paneling with reduced sheet thickness and improved flatness of the outer surfaces of the components. According to the invention, the improved properties over the known methods for designing and manufacturing the above-mentioned components by a wall module 1 with an outer panel with depending on the local stresses at certain intervals arranged integrated or integral stiffening elements 3, by a skeleton, which substantially only from depending on the local stresses arranged at certain intervals skeletons 4 and essentially requires no additional longitudinal profiles to stiffen the Außenbeblechung, by a production, pre-assembly and final assembly of the wall modules with simple positioning and joining devices with low production time through self-positioning and temporary self-fixation the thermal joining process, by small tolerance deviations in dimensional accuracy and flatness by means of reduced thermal influence and by a design for optimum use of modern thermal joining methods and modern cold forming process for the production of wall modules and achieved by the resulting from the overall system of all properties of the invention possible high degree of automation of the entire manufacturing process of the wall modules.

Description

The invention relates to a wall module for a component of a car body for a rail vehicle, a wall segment for a wall module, a car body component, a car body and a method for manufacturing (manufacturing, pre and final assembly) of components (side wall, end wall, roof) for the shell of car bodies in rail vehicle construction in differential construction.

From the prior art it is known that the components (side wall, end wall, roof) of car bodies are made of truss-like ribs, consisting of interconnected skeletons and longitudinal stiffeners and then connected thereto outer Bel. By way of example, this so-called "differential construction" in the DE 10 2008 048 083 A1 , of the EP 2 555 957 B1 ( DE 10 2010 014 962 A1 ) and the CN 204055793 U described. The production of the components (side wall, end wall, roof) usually takes place in such a way that the components for the fan-like skeleton of the components are positioned in a first step in devices and assembled therein by means of thermal joining methods. In a second step, outer sheet metal segments are placed on the framework and joined with each other and with the framework. The joining of the skeleton and the outer panel as well as their segments with each other takes place in the Usually by means of welded joints. In this case, no longer continuous welds are possible due to the design and the welding equipment must constantly change location and direction of their activity, resulting in low productivity and increased production times result. The design-related high number of welded joints also has the consequence that caused by thermal shrinkages, especially in the longitudinal direction of the components considerable tolerance deviations to the nominal dimensional accuracy and the thermal influence leads to buckling of the outer baffle between the fan-like areas. To maintain or reduce these changes in shape within predetermined limits, forcing high additional technical effort, in particular by thermal tensioning of the outer Beliech. As a rule, the fan-like skeletons consist of skeleton carriers arranged at specific intervals with a plurality of longitudinal profiles positioned between them and running parallel to the longitudinal axis of the car body. In particular, for the positioning and joining of the longitudinal profiles costly devices and time-consuming activities are required. The fan-like design of the framework also requires a complex programming and permanent interruption and repositioning of the welding equipment used in the thermal joining process. As a rule, the external paneling consists of prefabricated sheet metal segments whose joining process requires similarly time-consuming activities and time-consuming programming of the welding equipment used. The dependence on the required stiffness of the components, which is the ratio of the fan grid of the skeleton to the sheet thickness of the outer panel, requires the use of different sheet thicknesses or sheets with different strength properties for the outer paneling in order to achieve the specified component mass in the wall areas with high or low stress.

From the prior art it is known to produce the outer panel with an inwardly drawn and spot-welded to form a tubular bead reinforcement designed edge profile. By way of example, this technical solution is in the DD 274 793 B5 described.

The edge profile forms a mounting flange for the joining of two assembly units, which are joined by means of lock bolt connection. In the case of using the edge profile as a stiffening element for a Außenbebleching this would mean that when mounting a significant manual overhead for setting and a significant extra weight created by the introduced mass of the lock bolt connections.

From the prior art it is known to produce surface components with a Beblechung with this stiffening on the inside horizontally extending profiles. By way of example, this technical solution is in the DE 195 28 610 C1 described. Here, the joining legs of the horizontal stiffening profiles are notched and joined in sections by means of spot welding or short fillet welds to the Beblechung. This solution leads to a discontinuous stiffening of the Beblechung and thus requires an increase in the sheet thickness to achieve the required rigidity for the outer Beliche.

From the prior art, a method for producing a modular steel car body is known, in which the outer panel is formed with Beulsteifen provided cover sheets, which extend at certain intervals horizontally over the entire length of the car body. By way of example, this technical solution is in the DE 10 2006 038 058 A1 described. The Beulsteifen are thereby by T or. 1- profiles are formed, which are connected by means of thermal joining process or Davex technology with the cover plates and are thus provided as a first base member. In a following step, these first base elements are placed on second base elements (frames), which are previously positioned on the sub-frame, and thermally joined. This solution requires a high level of technical effort when joining the outer panel with the previously positioned on the frame frames and the condition of this assembly sequence joining position of the outer panel to the frames is not suitable for the use of modern thermal joining methods, such as laser welding.

Compared to this prior art, it is a first object of the present invention to provide an advantageous wall module and a favorable wall segment for a component of a wagon of a rail vehicle. It is a second object of the present invention to provide an advantageous body component and an advantageous body for a rail vehicle. Finally, it is a third object of the present invention to provide an advantageous method for producing a carbody component.

The first object is achieved by a wall module according to claim 1 or by a wall segment according to claim 8, the second object is achieved by a carbody component according to claim 16 or by a Wagenkaten according to claim 19, and the third object is achieved by a method according to claim 20 solved. The dependent claims contain advantageous embodiments of the invention.

• ∘ eine Außenbeblechung mit in Abhängigkeit von den lokalen Beanspruchungen in bestimmten Abständen angeordneten integrierten oder integralen Versteifungselementen enthält und dessen Gerippe im Wesentlichen nur noch aus in Abhängigkeit von den lokalen Beanspruchungen in bestimmten Abständen angeordneten Gerippeträgern besteht und im Wesentlichen ohne zusätzlich fächerartig angeordnete Längsprofile zur Versteifung der Außenbeblechung auskommt
• ∘ eine Fertigung, Vormontage und Endmontage der Wandmodule mit einfachen Positionierungs- und Fügevorrichtungen und mit geringem Fertigungszeitaufwand durch eine Selbstpositionierung und temporäre Selbstfixierung für den thermischen Fügeprozess der Außenbeblechung mit den Gerippeträgern ermöglicht
• ∘ geringe Toleranzabweichungen in Maßhaltigkeit und Ebenheit durch eine reduzierte thermische Beeinflussung aufweist
• ∘ eine örtlich erhöhte Ausnutzung der zulässigen Grenzbelastung der Werkstoffe durch die zur Anwendung kommenden Schweißnahtgestaltungen (vorzugsweise Stumpfnahtstöße) mit Bezug auf die Kerbfalllinien der geltenden Berechnungsvorschriften ermöglicht
• ∘ eine Reduzierung der verwendeten Blechdicken für die Außenbeblechung durch eine auf die Beanspruchungen optimierte Anordnung der integrierten oder integralen Versteifungselemente ermöglicht
• ∘ den optimalen Einsatz moderner thermischer Fügeverfahren durch eine Minimierung der Unterbrechungen und Minimierung der Richtungswechsel beim Fügeprozess der Wandmodule ermöglicht
• ∘ den optimalen Einsatz moderner Kaltumformungsverfahren wie bspw. das Rollprofilieren zur Herstellung der Wandmodule ermöglicht
• ∘ durch das Gesamtsystem der genannten Eigenschaften einen hohen Automatisierungsgrad des gesamten Fertigungsprozesses der Wandmodule und eine gute Zugänglichkeit für die üblichen Korrosionsschutzmaßnahmen ermöglicht

According to the invention, a wall module for the production of components (side wall, end wall, roof) for the shell construction of car bodies in rail vehicle construction is proposed, which:

• ∘ contains an outer panel with arranged depending on the local stresses at certain intervals integrated or integral stiffening elements and the skeleton consists essentially only of depending on the local stresses arranged at certain intervals skeletons and essentially without additional fan-like arranged longitudinal profiles for stiffening Außenbeblechung gets by
• ∘ enables production, pre-assembly and final assembly of the wall modules with simple positioning and joining devices and with low production time through a self-positioning and temporary self-fixation for the thermal joining process of the outer lining with the skeletons
• ∘ has low tolerance deviations in dimensional accuracy and flatness due to a reduced thermal influence
• ∘ allows a locally increased utilization of the permissible limit load of the materials by the applicable weld seam designs (preferably butt weld joints) with reference to the notch lines of the applicable calculation rules
• ∘ allows a reduction in the sheet thicknesses used for the external paneling by a stress-optimized arrangement of the integrated or integral stiffening elements
• ∘ enables optimum use of modern thermal joining methods by minimizing interruptions and minimizing the change of direction during the joining process of the wall modules
• ∘ enables optimal use of modern cold forming processes such as roll profiling for the production of wall modules
• ∘ allows a high level of automation of the entire production process of the wall modules and good accessibility for the usual corrosion protection measures by the overall system of the properties mentioned

• einem Abschnitt einer Außenbeblechung mit einer Innenfläche, welche dazu vorgesehen ist, im Wagenkasten in Richtung auf das Wageninnere zu weisen,
• einer Anzahl von linienförmigen Versteifungselementen, die sich im Wesentlichen parallel zueinander sowie längs dem Abschnitt der Außenbeblechung erstrecken und über die Innenfläche des Abschnitts der Außenbeblechung vorstehen, und
• Gerippeträgern, die sich im Wesentlichen parallel zueinander, senkrecht zu den Versteifungselementen und parallel zu dem Abschnitt der Außenbeblechung erstrecken und mit dem Abschnitt des Außenbeblechung stoffschlüssig verbunden sind. Dadurch sind die Außenbeblechung, die Versteifungselemente und die Gerippeträger derart miteinander verbunden, dass sie zusammenwirkend die in das Wandmodul eingeleiteten Druck-, Zug- und Schubkräfte sicher ertragen können, und dafür dergestalt ausgebildet sind, dass
• die Versteifungselemente sich über den Bereich mehrerer Gerippeträger hinweg unterbrechungsfrei erstrecken und ein integraler oder integrierter Bestandteil des Abschnitts der Außenbeblechung sind,
• die Gerippeträger an den Kreuzungsstellen mit den Versteifungselementen Formausklinkungen aufweisen, die die durchlaufenden Versteifungselemente aufnehmen.

An inventive wall module for a component such as side wall, end wall, roof or the like of a car body of a rail vehicle consists of:

• a portion of an outer panel having an inner surface which is intended to point in the car body towards the car interior,
• a plurality of line-shaped stiffening elements extending substantially parallel to each other and along the portion of the outer panel and protruding beyond the inner surface of the portion of the outer panel, and
• Rack supports, which extend substantially parallel to each other, perpendicular to the stiffening elements and parallel to the portion of the Außenbeblechung and are integrally connected to the portion of the Außenbeblechung. As a result, the outer panel, the stiffening elements and the ribbed girders are connected to one another in such a way that they can cooperatively bear the compressive, tensile and shear forces introduced into the wall module, and are designed in such a way that
• the stiffening elements extend uninterrupted over the area of a plurality of skeleton carriers and are an integral part of the section of the external arch,
• the skeletons at the intersections with the stiffening elements have Formausklinkungen that receive the continuous stiffening elements.

In this case, the section of the outer panel can have a flat or arched outer surface and a constant or variable sheet thickness in a direction transverse to the stiffening elements, and the stiffening elements can each consist in particular of a rib profile with a hollow body profile arranged thereon.

The wall module according to the invention is characterized in that some or all Formausklinkungen have a shape after positioning the Gerrifeträger to the portion of the outer panel with the stiffening elements in cooperation with the stiffening elements of the outer panel already without the cohesive connection a positive or non-positive fixation of the skeletal support relative bring to the section of the outer panel with the stiffening elements.

An integral part of the external paneling is an integral part of the external paneling. For example. For example, one or more of the stiffening elements may be formed by means of a primary shaping or forming process, preferably Cold forming, to be made as an integral part of the outer panel. In contrast, an integral part of the outer panel is to be understood as a component which has been formed separately and subsequently joined to the outer panel. For example. For example, one or more of the stiffening elements can be integrated into the outer panel by means of a thermal joining method.

The portion of the outer panel of the wall module may consist of one or more wall segments, each having a transverse extension and a greater longitudinal dimension relative to the transverse extension, each comprising one or more integral or integral stiffening elements extending along the longitudinal extent and parallel to the inner surface of the wall module Wall modules extend. The individual wall segments can then be joined in a simple manner, for example by means of a linearly moving welding device.

In the wall module according to the invention, the girder carriers can contain one or more of the form notches which are designed in such a way that, after the girder carriers have been mechanically joined to the stiffening elements, the girder carriers contact them in a touching manner over substantially their entire length on the outer plate or are positioned at a defined spacing. This facilitates the subsequent joining of the skeletons with the outer panel.

An inventive wall segment for a wall module of a component of a car body of a rail vehicle consists of a strip-shaped portion of a steel sheet of Außenbeblechung, one or more parallel to the inner surface of the wall segment extending and over the inner surface protruding stiffening elements, each consisting of a web profile and a hollow body profile.

In a first embodiment of the wall segment of the strip-shaped portion on the one hand and the web profile and the hollow body profile on the other hand made separately and joined together by a cohesive joining process. There is a possibility that the Web profile and the hollow body profile produced separately and joined together by a cohesive joining process. For example. For example, the web profile and the hollow body profile can be joined together by means of laser or laser hybrid welding. But the web profile and hollow body profile can also be made in one piece, for example. By extrusion. In addition, they can have locally variable sheet thicknesses.

In a second embodiment of the wall segment of the strip-shaped portion, the web profile and the hollow body profile are made in one piece as a strip profile. In particular, they can be produced as urgestformtes strip profile. Roll forming can be used, for example, for primary shaping. Also in this embodiment, the web profile and the hollow body profile can have locally variable sheet thicknesses. A gap of the web profile attributable to the primary molding can be closed with a material which inhibits crevice corrosion, in particular by a cohesive joining process, preferably by a laser welding process or laser brazing process, and can preferably be filled on the outside surface of the external skin.

A vehicle body component according to the invention for a rail vehicle consists of one or more of the wall modules according to the invention. In her recesses, such as window openings, door cutouts, media feedthroughs or the like can be cut out with high accuracy of fit. In these recesses reinforcing profiles, preferably by laser or laser hybrid welding cohesively and as a T-joint on the inside of the recesses can run circumferentially. In addition, in other wall areas, in which particularly high stresses are to be endured, additional stiffening profiles designed as a function of the stress and installation situation, such as, for example, door pillars or gullies, may be arranged.

• Herstellung wenigstens eines Abschnittes der Außenbeblechung aus erfindungsgemäßen Wandsegmenten sowie Einlegen und Fixieren der Außenbeblechung in einer Haltevorrichtung derart, dass die Versteifungselemente frei zugänglich zur Positionierung der Gerippeträger sind,
• Herstellung der Gerippeträger mit den Formausklinkungen und Positionierung der Gerippeträger zur Außenbeblechung durch Einlegen in die Haltevorrichtung,
• mechanisches Zusammenfügen der Gerippeträger mit den Versteifungselementen derart, dass die Gerippeträger an den Versteifungselementen formschlüssig positioniert oder federnd kraftschlüssig fixiert werden, wobei die Stege der Gerippeträger an der Außenbeblechung zur Anlage kommen oder in definiertem Abstand zur Außenbeblechung positioniert sind,
• thermisches Fügen der Gerippeträger mit der Außenbeblechung mittels eines oder mehrerer thermischer Fügeverfahren und
• falls erforderlich, Herstellung der Ausschnitte für Fenster, Türen, Mediendurchführungen und dergleichen in einem Wandmodul nach dem Fügen der Gerippeträger mit der Außenbeblechung mittels eines thermischen und/oder spanenden Trennverfahrens und mechanisches Zusammenfügen der Verstärkungsprofile in den Ausschnitten mit dem Wandmodul in einer Haltevorrichtung und anschließendes thermisches Fügen der Anordnung mittels eines oder mehrerer thermischer Fügeverfahren.

The method according to the invention for producing a carbody component comprises the following steps:

• Production of at least a portion of the outer panel of wall segments according to the invention and inserting and fixing the Außenbeblechung in a holding device such that the stiffening elements are freely accessible for positioning of the skeletons,
• Production of the girder carriers with the form notches and positioning of the girder carriers to the outer plate by insertion into the holding device,
• mechanically joining the skeletal support with the stiffening elements such that the skeletal supports are positively positioned on the stiffening elements or fixed in a resiliently non-positive manner, wherein the webs of the skeletal support come to rest on the outer arch or are positioned at a defined distance from the outer arch,
• thermal joining of the skeletons with the outer panel by means of one or more thermal joining methods and
• if necessary, manufacturing the cutouts for windows, doors, media feedthroughs and the like in a wall module after joining the skeleton beams to the outer panel by means of a thermal and / or cutting separation method and mechanically joining the reinforcement profiles in the cutouts to the wall module in a fixture and then thermally Joining the assembly by means of one or more thermal joining methods.

The inventive method is characterized in that some or all Formausklinkungen have a shape after inserting the stiffening elements of the section of the outer plate in the Formausklinkungen the webs of the skeletons and prior to thermal joining in cooperation with the stiffening elements of the outer Beliech a positive or non-positive Fixation of the ribbed beams relative to the section of the outer sheet with the stiffening elements bring about.

In addition, the method may also include preparing the first stage of a corrosion protection (prime) finish of the component including the void preservation of the stiffening elements.

The production of the external paneling can be carried out essentially by the uninterrupted joining of wall segments which extend over the entire length of the car body component.

The joining of the outer panel with the skeletal support to a wall module can be done by the positive positioning and / or non-positive fixation without additional clamping devices for fixing the skeletal support on the Außenbeblechung in the thermal joining process. The skeleton formed by the skeletons consists only of the skeletons without additional fan-like arranged longitudinal profiles for stiffening the Außenbeblechung.

An inventive car body for a rail vehicle comprises at least one car body component according to the invention. A railcar body made in accordance with this invention therefore comprises the feature that the side walls or portions of the side walls, the end walls or portions of the end walls, the roof or a portion of the roof are made with wall modules. The wall modules comprise in particular the design of the outer panel made of wall segments with integral or integral stiffening elements which are guided without interruption by skeletal support, the skeleton design substantially without the use of additional longitudinal profiles for stiffening the outer panel and the self-positioning feature and possibly the temporary self-fixing of the skeletal support over the Stiffening elements of the outer paneling. It is understood, however, that in wall areas where particularly high voltages may occur, such as e.g. in the field of cutouts for windows, doors, media feedthroughs and the like, further reinforcing profiles can be arranged.

The components produced according to the invention, such as side wall, end wall, roof or the like offer the advantage that they are equipped with a high dimensional accuracy and significantly lower flatness deviations compared to the previously known manufacturing and design methods can be produced and by their design the optimal use of modern manufacturing and thermal joining methods, in particular roll profiling, laser cutting and laser welding allow. Particularly advantageous is the possibility to produce wall modules that extend over the entire length (eg, a side wall or a roof) or width (eg, an end wall) of a component for a car body. If separately produced stiffening elements are to be integrated into the outer panel, long, uninterrupted welds and (particularly advantageous when using laser welding methods) the simultaneous parallel operation of multiple welding units are possible. When using a Außenbeblechung with integral stiffening elements longitudinal seams are essentially only required for the joining of the thin sheet strip profiles. The strip profile used in this case is particularly suitable for the production process roll profiling.

Manufacturing technology, it may be a particular advantage, necessary cutouts for windows, doors, media feedthroughs and the like in a wall module only after the joining of the skeletons with the outer plate by means of a thermal and / or cutting separation process to introduce.

The invention makes it possible in particular by the adapted arrangement of the integrated or integral stiffening elements of the outer panel comparable structural properties with reduced sheet thickness compared to the previously known constructions.

For the production, pre-assembly and final assembly of the wall modules designed according to the invention, the possibility of self-positioning and temporary self-fixing necessitates a significantly lower device and joining time outlay compared with the previously known production methods and designs.

The use of inventive wall modules allows a high degree of automation of the entire manufacturing process of the wall modules over the previously known manufacturing processes and designs.

Railcar bodies must be designed for a long service life, e.g. be designed for 30 or 35 years. Therefore, their corrosion protection is of great importance. The inventive design of the components and their arrangement has good accessibility for conventional corrosion protection measures. When components are made by roll profiling, filling between them existing column prevents crevice corrosion. Even in hollow sections unavoidable cavity is common access cavity preservation measures.

An inventive design of the stiffening elements also has special advantages for the interior of the car bodies. While it is common in the car bodies manufactured according to the prior art, for the attachment of a thermally and acoustically acting inner insulation and / or for the cultivation of media lines, partitions, luggage reception facilities, lighting and air conditioning and wall coverings, etc., a high number of fasteners in addition to weld, can be largely or completely waived in the inventive design of a car body, if used for the connection of said interior fittings fastener (clamp elements), which are designed such that they are positively and / or non-positively connectable with the stiffening elements.

Due to the design according to the invention and the possible high amount of cold forming component in the manufacturing process, it is possible to minimize the heat input acting on the outer panel, the resulting distortion and the corrective measures and production time required for its elimination or reduction. At the same time, the solution according to the invention enables a constructive optimization of the components with regard to the necessary material thicknesses and the space that is appropriate (further or more closely spaced) Distribution of the stiffening elements, which leads to a significant saving in material and weight over the known prior art arrangements and methods for a significant material and weight and over the life of a rail vehicle with an inventively designed car body to a significant saving in operating energy.

Figur 1

zeigt eine isometrische Darstellung eines erfindungsgemäß gestalteten Wandmoduls.

Figur 2

zeigt eine isometrische Detaildarstellung eines Ausschnitts des Wandmoduls aus Figur 1.

Figuren 3A-E

zeigen verschiedene Gestaltungsmöglichkeiten des Hohlkörperprofils von Versteifungselementen des Wandmoduls aus Figur 1 in einer Querschnittsansicht.

Figur 4

zeigt ein erstes Ausführungsbeispiel für ein Wandsegment des Wandmoduls aus Figur 1 in einer Querschnittsansicht.

Figur 5

zeigt ein zweites Ausführungsbeispiel für ein Wandsegment des Wandmoduls aus Figur 1 in einer Querschnittsansicht.

Figur 6

zeigt eine Ausgestaltung der Selbstpositionierung eines Gerippeträgers im Wandmodul aus Figur 1.

Figur 7

zeigt eine alternative Ausgestaltung der Selbstpositionierung eines Gerippeträgers mit Selbstfixierung.

Figur 8

zeigt noch eine alternative Ausgestaltung der Selbstpositionierung eines Gerippeträgers mit Selbstfixierung.

Figur 9

zeigt eine isometrische Darstellung eines Seitenwandmoduls.

Figur 10

zeigt eine isometrische Darstellung einer Seitenwand.

Figur 11

zeigt einen beispielhaften Schnitt durch die Seitenwand aus Figur 10.

Further features, properties and advantages of the present invention will become apparent from the following description of embodiments with reference to the accompanying figures.

FIG. 1

shows an isometric view of a wall module designed according to the invention.

FIG. 2

shows an isometric detail of a section of the wall module FIG. 1 ,

FIGS. 3A-E

show different design options of the hollow body profile of stiffening elements of the wall module FIG. 1 in a cross-sectional view.

FIG. 4

shows a first embodiment of a wall segment of the wall module FIG. 1 in a cross-sectional view.

FIG. 5

shows a second embodiment of a wall segment of the wall module FIG. 1 in a cross-sectional view.

FIG. 6

shows an embodiment of the self-positioning of a skeleton carrier in the wall module FIG. 1 ,

FIG. 7

shows an alternative embodiment of the self-positioning of a skeletal support with self-fixation.

FIG. 8

shows an alternative embodiment of the self-positioning of a skeletal support with self-fixation.

FIG. 9

shows an isometric view of a sidewall module.

FIG. 10

shows an isometric view of a sidewall.

FIG. 11

shows an exemplary section through the side wall FIG. 10 ,

FIG. 1 shows an isometric view of an embodiment of an inventive designed wall module 1 for a rail vehicle, and FIG. 2 shows an enlarged section FIG. 1 , The wall module 1 consists of the outer panel 2 with integrated or integral stiffening elements 3 and a skeleton of ribs 4 arranged at certain intervals. In this example, the stiffening elements 3 and the perpendicular thereto skeletal support 4 are arranged and connected to the outer panel 2 that the Wall module 1 without a fan-like framework with a variety of additional horizontal stiffening profiles manages.

The wall module 1 is constructed from a plurality of wall segments 11, 11 ', which each include a strip-shaped segment 2 a of the outer panel 2. In the illustrated wall module 1 different wall segments 11 and 11 'are present. The wall segments 11 each have a longitudinal extent L and a transverse extent Q, wherein the longitudinal extent L is greater than the transverse extent Q. In each wall segment 11, a stiffening element 3 is integrally formed or integrally formed, which extends linearly along the longitudinal extent L of the wall segment 11 and protrudes beyond the inner surface 22 of the outer panel 2. Each stiffening element 3 is guided without interruption by the skeletal support 4. This in FIG. 1 Wall element 11 'to be recognized has a larger transverse extent compared to the wall elements 11. Moreover, it is with a plurality of provided parallel to each other, integrally or integrally formed stiffening elements 3, which extend in the longitudinal extension and protrude beyond the inner surface 22 of the outer panel 2. Along linear welds 21, the segments 2 a of the outer panel 2 and thus the wall segments 11, 11 ', for example. Welded together by means of laser or laser hybrid welding.

Each stiffening element 3 comprises a web profile 5 integrally or integrally formed with the outer plate 2 and a hollow body profile 6 arranged at the end of the web profile 5 remote from the outer plate 2 FIGS. 3A-E show various design options of the hollow body profile 6. In general, the hollow body profile 6 a symmetrical or asymmetrical cross-section and straight or curved profile sections which enclose a central profile opening 23, ..

FIG.4 shows an example of the configuration of a wall segment 11. It can be seen a section of the strip-shaped segment 2a of the outer panel 2 and an integrated stiffening element 3a. The stiffening element 3a runs uninterrupted over the entire longitudinal extent L of the wall segment and consists in the present example of a welded to the strip-shaped segment 2a of the outer panel 2 along a weld 14 web profile 5 and welded to the web profile 5 hollow body profile 6. The welding of the web profile 5 at The strip-shaped segment 2 a of the outer panel 2 takes place in the present example by means of laser welding. It is particularly advantageous in this case that the welded joints with the stiffening elements 3 a extending without interruption over the entire length of a wall segment 11 can be produced by uninterrupted weld seams.

FIG.5 shows an alternative example of the configuration of the wall segment 11. As in FIG. 4 are a section of the strip-shaped segment 2a of the outer panel 2 and a stiffening element 3b can be seen. Unlike the in FIG. 4 illustrated embodiment of the wall element 11 is the Stiffening element 3b formed in the present embodiment, integrally with the strip-shaped segment 2a of the outer panel 2. The hollow section 6 in this case has only an almost completely circular cross section. In the area of the connection of the hollow profile 6 to the web profile 5, a bulge 25 of the hollow profile 6 in the direction of the web profile is present. As a result, an increased elasticity of the hollow profile 6 is achieved at forces acting on the hollow profile 6 within the cross-sectional area.

In the FIG. 5 shown special shape of the web profile 5, the cylindrical hollow profile 6 and the strip profile 2a is preferably made by roll profiling. In this case, the gap 12 in the region of the web profile 5 at least on the outer surface 24 of the strip-shaped segment 2a of the outer panel 2 can be filled surface-level. Particularly advantageous in the sense of corrosion prevention is when the gap 12 is closed over its entire gap length SL. Preferably, the filling on the outer surface 24 and the closing of the gap 12 by a cohesive joining process, preferably by means of laser soldering or gluing or by another welding method in conjunction with a Spaltkorrosionshindernden material.

FIG.6 shows an embodiment of a self-positioning of a skeletal support 4 on the outer panel 2 via the integrated or integral stiffening element 3. In this case, the contact contour 9 between the outer panel 2 and the web 8 of the skeletal support 4 a straight line or, if the outer panel 2 of the wall module to be curved be a curve corresponding curve. For self-positioning, the stiffening element 3 is introduced into a form notching 7 in the web 8 of the skeletal support 4. The Formausklinkung 7 has an end portion 7a, whose cross section is formed substantially complementary to the cross section of the hollow profile 6. The end portion 7a is separated from an insertion portion 7b whose opening width is slightly larger than the diameter of the hollow profile 6.

FIG. 7 shows an embodiment of the self-positioning of a skeletal support 4 on the outer panel 2 with temporary self-fixation, in which a temporary self-fixation by means of positive clamps via an integral stiffening element 3b and complementary to the integral stiffening element 3b arranged at least partially positively to the hollow profile designed Formausklinkung 7 takes place in the web 8 of the skeletal support 4. The Formausklinkung 7 has an end portion 7a, whose cross section is formed substantially complementary to the cross section of the hollow profile 6. The end section 7a is separated from an insertion section 7b whose opening width is slightly larger than the diameter of the hollow section 6 by a pawl section 7c whose opening width is slightly smaller than the diameter of the hollow section 6 due to clamping lugs 10 arranged on both sides. When inserting the stiffening element 3 in the Formausklinkung 7, the hollow profile is compressed when passing the pawl portion 7 c through the clamping lugs 10. After passing through the pawl portion 7c, the hollow profile 6 expands again in the end portion 7a due to its elasticity, so that the hollow profile 6 is fixed positively in the end portion 7a by means of the pawl portion 7c. The opening width of the clamping lugs 10 is selected so that when clamping the skeletal support 4 on the stiffening element 3b only elastic, but no or only a slight plastic deformation of the hollow body profile 6 occurs without the resilient adhesion is released. For the production of the Formausklinkungen 7, regardless of the specific configuration of Formausklinkungen 7 preferably laser cutting should be used, since the required high form and accuracy of fit of the components can be achieved.

FIG.8 shows an alternative embodiment of the self-positioning of a skeletal support 4 on the outer panel 2 with temporary self-fixation. While in the in FIG. 7 shown embodiment of the self-positioning a two-sided arrangement of clamping lugs 10 in the pawl portion 7c is used, takes place in the present embodiment, a temporary self-fixation by a pairing of asymmetric Formausklinkungen 7 instead. In a pair of asymmetric Formausklinkungen 7, each Formausklinkung only a pawl portion 7c, wherein the pawl portions 7c in the two Formausklinkungen 7 of the pair different sides of the Formausklinkung 7 are arranged so that they can be converted into each other by an Achsenspiegelung. In other words, in a pair of Formausklinkungen 7, the respective pawl portions 7 c are oriented differently. The pairs of Formausklinkungen 7 are distributed over the respective skeletal support 4, wherein the Formausklinkungen 7 of a pair of Formausklinkungen 7 need not necessarily be arranged side by side. The elastic clamping of the integrated stiffening element 3 in the skeletal support 4 is achieved by the cooperation of the pawl portions 7 c of a pair of Formausklinkungen 7. Although the Formausklinkungen 7 can be converted into each other in the present embodiment by an axis mirror, this configuration is not mandatory. It is only essential that the two Formausklinkungen 7 of a pair generated by the asymmetric and opposite, but not necessarily mirrored, aligned arrangement of the pawl portion 7c in its hollow profile laterally comprehensive area an oppositely acting clamping force on the spring action of the web profile 5, so that the Formausklinkungen 7 of the pair can bring about a positive connection with the associated stiffening elements 3. In this case, said asymmetry is chosen so that when clamping the skeletal support 4 on the stiffening element 3a only elastic or no failure-promoting plastic deformation of the web profile 5 and the hollow body profile 6 occur, however, the resilient adhesion is given. After clamping, no voltage is allowed.

FIG.9 shows the isometric representation of a side wall module 13 in the joining position of the skeletal support 4 to the outer panel 2 with the integrated or integral stiffening elements 3. It may be advantageous to elastically brace the skeletal support 4 when positioned on the outer panel 2 by means of a device so that spread the clamping lugs of Formausklinkungen so far that the engagement can be done on the outer panel 2 associated stiffening elements 3 without increased joining effort. After snapping the clamping lugs of the joining process between the Außenbeblechung 2 and the webs of the skeletons 4 are preferably carried out by means of laser or laser hybrid welding 14 as a T-joint connection.

FIG.10 shows the isometric view of a designed as a side wall 17 car body component in joining position consisting of a side wall module 13 after joining the skeletal support 4 in the side wall module 13 by means of a thermal and / or cutting separation introduced cuts 26, 27 for windows, doors, media feedthroughs and the like and in the area of cutouts 26, 27 for windows, doors, media feedthroughs and the like for local stiffening arranged and thermally joined reinforcing profiles 18, door pillars 19 and the Voutenträger 20. For the production of the cutouts, the thermal cutting method laser cutting or a mechanical separation method should preferably be used , because so the required high form and accuracy of fit of the components can be achieved.

FIG.11 shows an exemplary section through the representation of the component side wall 17 in the joining of the side wall module 13 with the T-shaped peripheral reinforcing profile 18, wherein the entire contact surface is materially joined preferably by laser or laser hybrid weld 14.

• Herstellung wenigstens eines Abschnittes der Außenbeblechung 2 aus Wandsegmenten 11,
• Einlegen und Fixieren der Außenbeblechung 2 in einer Haltevorrichtung derart, dass die Versteifungselemente 3 frei zugänglich zur Positionierung der Gerippeträger 4 sind,
• Herstellung der Gerippeträger 4 mit den Formausklinkungen 7 und Positionierung der Gerippeträger 4 zur Außenbeblechung 2 durch Einlegen in die Haltevorrichtung,
• mechanisches Zusammenfügen der Gerippeträger 4 mit den Versteifungselementen 3 derart, dass die Gerippeträger 4 an den Versteifungselementen 3 formschlüssig positioniert oder federnd kraftschlüssig fixiert werden, wobei ihre Stege 8 an der Außenbeblechung 2 zur Anlage kommen oder in definiertem Abstand zur Außenbeblechung 2 positioniert sind,
• thermisches Fügen der Gerippeträger 4 mit der Außenbeblechung 2 mittels eines oder mehrerer thermischer Fügeverfahren und
• falls erforderlich, Herstellung der Ausschnitte 26, 27 für Fenster, Türen, Mediendurchführungen und dergleichen in einem Wandmodul nach dem Fügen der Gerippeträger 4 mit der Außenbeblechung 2 mittels eines thermischen und / oder spanenden Trennverfahrens und mechanisches Zusammenfügen von Verstärkungsprofilen 18 in den Ausschnitten 26, 27 mit dem Wandmodul in einer Haltevorrichtung und anschließendes thermisches Fügen der Anordnung mittels eines oder mehrerer thermischer Fügeverfahren.

With the aid of the invention, a body component can be made by performing the following steps:

• Production of at least a section of the outer panel 2 from wall segments 11,
• Inserting and fixing the outer panel 2 in a holding device such that the stiffening elements 3 are freely accessible for positioning the skeletal support 4,
• Production of the skeletal support 4 with the Formausklinkungen 7 and positioning of the skeletal support 4 to the outer Bel 2 by inserting into the holding device,
• mechanically joining the skeletal support 4 to the stiffening elements 3 in such a way that the skeletal supports 4 are positively fixed or resiliently fixed to the stiffening elements 3, their webs 8 coming into contact with the outer arch 2 or being positioned at a defined distance from the outer arch 2,
• thermal joining of the skeletal support 4 with the outer panel 2 by means of one or more thermal joining methods and
• if necessary, manufacturing the cutouts 26, 27 for windows, doors, media feedthroughs and the like in a wall module after joining the skeletal supports 4 to the outer panel 2 by means of a thermal and / or cutting separation process and mechanical joining of reinforcement profiles 18 in the cutouts 26, 27 with the wall module in a holding device and subsequent thermal joining of the arrangement by means of one or more thermal joining methods.

This may be followed by the production of the first stage of anti-corrosive treatment (primer) of the component, including the cavity preservation of the stiffening elements.

The production of the outer panel 2 can be carried out essentially by the uninterrupted joining of wall segments 11, which extend over the entire length of the car body component.

In the context of the method, the joining of the outer panel 2 with the skeletal supports 4 to a wall module 1 by the positive positioning and / or non-positive fixation without additional clamping devices for fixing the skeletal support 4 on the Außenbeblechung carried out in the thermal joining process. The skeleton formed by the skeletal support 4 consists only of the skeletons 4 without additional fan-like arranged longitudinal profiles for stiffening the Außenbeblechung second

LIST OF REFERENCE NUMBERS

1

wall module

2

Outer panel (a: strip-shaped section)

3

Stiffening element (a: integrated, b: integral)

4

skeleton carrier

5

web profile

6

Hollow element

7

Formausklinkung

8th

web

9

contact contour

10

clamping nose

11

wall segment

12

gap

13

A side panel module

14

Laser or laser hybrid weld

17

Side wall

18

reinforcing profiles

19

door pillars

20

haunch

21

Weld

22

palm

23

profile opening

24

outer surface

25

bulge

26

neckline

27

neckline

Claims (15)

Wall module for a component of a car body of a rail vehicle, comprising: a portion of an outer panel (2) having an inner surface (22), - a number of linear stiffening elements (3) extending substantially parallel to each other and along the portion of the outer panel (2) and projecting beyond the inner surface (22) of the portion of the outer panel (2), and Skeleton supports (4), which extend substantially parallel to one another, perpendicular to the stiffening elements (3) and parallel to the section of the outer panel (2) and are materially connected to the section of the outer panel (2), in which the stiffening elements (3) extend uninterrupted over the area of a plurality of skeletal supports (4) and are an integral part of the section of the external arch (2), - have the skeletons (4) at the intersection with the stiffening elements (3) Formausklinkungen (7) which receive the continuous stiffening elements (3), characterized in that - Some or all Formausklinkungen (7) have a shape that after positioning of the skeletal support (4) to the section of Outer panel (2) with the stiffening elements (3) in cooperation with the stiffening elements (3) of the outer panel (2) already without the cohesive connection a positive or non-positive fixation of the skeletal support (4) relative to the portion of the outer panel (2) with the stiffening elements ( 3). Wall module according to claim 1, characterized in that the section of the outer panel (2) of the wall module consists of one or more wall segments (11) each having a transverse extent (Q) and a relative to the transverse dimension (Q) greater longitudinal extent (L), the or each comprising one or more integral or integral stiffening elements (3) extending along the longitudinal extent (L) and parallel to the inner surface (22) of the wall module. Wall module according to claim 1 or claim 2, characterized in that the ribbed supports (4) contain one or more of the Formausklinkungen (7), which are designed such that after the mechanical joining of the skeletal support (4) with stiffening elements (3) the Gerifeträger ( 4) over substantially the entire length of the outer panel (2) bear touching or positioned at a defined distance. Wall module according to one of claims 1 to 4, characterized in that one or more of the stiffening elements (3) by means of a thermal joining method in the outer panel (2) are integrated or that one or more of the stiffening elements (3) are an integral part of the Außenbeblechung. Wall segment (11) for a wall module of a component of a car body of a rail vehicle, consisting of a strip-shaped section (2a) of a steel sheet of the outer panel, one or more parallel to the inner surface (22) of the wall segment extending and over the inner surface (22) projecting stiffening elements (3), each consisting of a web profile (5) and a hollow body profile (6). Wall segment according to claim 5, characterized in that the strip-shaped section (2a) on the one hand and the web profile (5) and the hollow body profile (6) on the other hand, be produced separately and joined together by a bonding technique and / or the bar profile (5) and the hollow body profile (6) are manufactured separately and joined together by a cohesive joining process. Wall segment (11) according to claim 5, characterized in that the web profile (5) and the hollow body profile (6) are made in one piece or the strip-shaped portion (2a), the web profile (5) and the hollow body profile (6) in one piece as a strip profile produced are. Wall segment (11) according to Claim 7, characterized in that a gap (12) of the web profile (5) due to the reshaping is closed with a material which prevents crevice corrosion and is filled on the outside of the section of the outer baffle (2). Car body component for a rail vehicle, characterized in that it consists of one or more of the wall modules according to claims 1 to 4. Car body for a rail vehicle, characterized in that it contains at least one car body component according to claim 9. A method of manufacturing a body component according to claim 9, comprising the steps of: - Providing at least a portion of the outer panel (2) with a number of line-shaped stiffening elements (3), the extending substantially parallel to each other and along the portion of the outer panel (2) and projecting beyond the inner surface (22) of the portion of the outer panel (2) and of ribbed beams (4) with webs (8) in which Formausklinkungen (7) are formed . Inserting and fixing the portion of the outer panel (2) in a holding device in such a way that the stiffening elements (3) are freely accessible for the positioning of the ribbed supports (4), - Positioning the skeletal support (4) to the portion of the outer panel (2) by insertion into the holding device, wherein the stiffening elements (3) of the portion of the outer panel (2) in the Formausklinkungen (7) of the webs (8) of the skeletons (4) introduced whereby the ribbed beams (4) are positioned, and wherein the webs (8) of the ribbed beams (4) come into contact with the outer sheet (2) or are positioned at a defined distance from the portion of the outer sheet (2), thermally joining the ribbed beams (4) to the section of the outer sheet (2) by means of one or more thermal joining methods, characterized in that - Some or all Formausklinkungen (7) have a shape that after the insertion of the stiffening elements (3) of the section of the outer panel (2) in the Formausklinkungen (7) of the webs (8) of the skeletons (4) and before the thermal joining in Cooperation with the stiffening elements (3) of the outer panel (2) bring about a positive or non-positive fixation of the skeletal support (4) relative to the portion of the outer panel (2) with the stiffening elements (3). The method of claim 11, wherein providing at least a portion of the outer panel (2) comprises forming the at least a portion of the outer panel (2). The method of claim 11, wherein forming the at least one portion of the outer panel (2) comprises uninterruptedly joining wall segments (11) according to any one of claims 5 to 8 extending the full length of the body component. The method of claim 13, wherein forming the at least one portion of the outer panel (2) also comprises forming the wall segments (11) for the at least one portion of the outer panel (2) by prototyping or by forming a sheet. Method according to one of claims 11 to 14, characterized in that the thermal joining of the portion of the outer panel (2) with the skeletal supports (4) to a wall module (1) by the positive or non-positive fixing without additional clamping devices for fixing the skeletal support (4 ) takes place on the outer panel during the thermal joining process and that the skeleton formed by the skeletal supports (4) consists only of the skeletal beams (4) without additional fan-like arranged longitudinal profiles for stiffening the Außenbeblechung (2).

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