EP3369638B1 - 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

Description

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

It is known from the prior art that the components (side wall, end wall, roof) of car bodies are made from lattice-like frameworks, consisting of interconnected framework beams and longitudinal stiffeners and a subsequently connected external sheet metal. This so-called "differential design" is exemplary in the EP 2 483 123 A0 ( WO 2011/038755 A1 ), the DE 10 2008 048 083 A1 , 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, front wall, roof) usually takes place in such a way that the components for the fan-like framework of the components are positioned in devices in a first step and then joined together using thermal joining processes. In a second step, outer sheet metal segments are placed on the framework and joined both with one another and with the framework. The framework and the outer sheet metal as well as their segments are usually joined to one another by means of Welded joints. Due to the design, longer, continuous welded connections are not possible and the welding devices have to constantly change their location and direction, which results in low productivity and increased production times. The design-related high number of welded joints also means that thermal shrinkage, especially in the longitudinal direction of the components, results in significant tolerance deviations from the nominal dimensional accuracy and the thermal influence leads to bulging of the outer sheet metal between the fan-like supported areas. Keeping these changes in shape within specified limits or reducing them requires a high level of additional technical effort, in particular through thermal stressing of the outer sheet metal. The fan-like frameworks generally consist of framework girders arranged at certain intervals with a multiplicity of longitudinal profiles that are positioned between them and run parallel to the longitudinal axis of the car body. In particular for the positioning and joining of the longitudinal profiles, expensive devices and manufacturing-time-consuming activities are required. The fan-like design of the framework also requires complex programming and constant interruption and repositioning of the welding devices used during the thermal joining process. The outer sheet metal usually consists of pre-assembled sheet metal segments, the joining process of which requires similarly manufacturing-time-consuming activities and complex programming of the welding equipment used. The dependency on the required stiffness of the components from the ratio of the fan grid of the framework to the sheet thickness of the outer sheet metal requires the use of different sheet metal thicknesses or sheets with different strength properties for the outer sheet metal in order to achieve the specified component mass in the wall areas with high or low stress.

It is known from the prior art to manufacture the outer sheet metal with an edge profile that is drawn inwards and is spot-welded to form a tubular bead reinforcement. This technical solution is exemplary in the DD 274 793 B5 described.

The edge profile forms a mounting flange for the joint between two assembly units that are joined by means of locking ring bolts. If the edge profile was used as a stiffening element for outer sheet metal, this would lead to considerable additional manual effort for setting and considerable additional weight due to the mass of locking ring bolt connections introduced during assembly.

It is known from the prior art to manufacture surface components with sheet metal with these stiffening profiles running horizontally on the inside. This technical solution is exemplary in the DE 195 28 610 C1 described. The joining legs of the horizontal stiffening profiles are notched and joined to the sheet metal in sections by means of spot welding or short fillet welds. This solution leads to a discontinuous stiffening of the sheet metal and thus requires an increase in the sheet thickness to achieve the required rigidity for the outer sheet metal.

Out U.S. 5,267,515 B, a vehicle body for a rail vehicle is known, which is constructed from extruded metal strips, each of which has a protruding rib with a T-shaped profile. Frame elements are welded to the ribs. The metal strips are also welded together.

A method for producing a modular steel car body is known from the prior art, in which the outer sheet metal is formed with cover plates provided with buckling stiffeners, which extend horizontally at certain intervals over the entire length of the car body. This technical solution is exemplary in the DE 10 2006 038 058 A1 described. The bulge stiffeners are thereby by T or. I-profiles are formed, which are connected to the cover sheets by means of thermal joining processes or Davex technology and are thus provided as a first base element. In a subsequent step, these first base elements are placed on second base elements (frames), which are previously positioned on the subframe, and thermally joined. This solution requires a high technical effort when joining the External sheet metal with the frames previously positioned on the subframe and the joining position of the external sheet metal to the frames resulting from this assembly sequence is not suitable for the use of modern thermal joining processes such as laser welding.

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

The first object is achieved by a wall module according to claim 1, the second object is achieved by a car body component according to claim 5 or by a car box according to claim 6, and the third object is achieved by a method according to claim 7. The dependent claims contain advantageous embodiments of the invention.

• o 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, front wall, roof) for the shell construction of car bodies in rail vehicle construction is proposed, which:

• o contains an outer sheet metal with integrated or integral stiffening elements arranged at certain intervals depending on the local stresses and whose framework consists essentially only of structural girders arranged at certain intervals depending on the local stresses and essentially without additional fan-like longitudinal profiles for stiffening the Outer sheet metal comes from
• ∘ enables production, pre-assembly and final assembly of the wall modules with simple positioning and joining devices and with little production time expenditure through self-positioning and temporary self-fixing for the thermal joining process of the outer sheet metal with the framework girders
• ∘ has low tolerance deviations in dimensional accuracy and evenness due to reduced thermal influence
• ∘ enables a locally increased utilization of the permissible limit load of the materials through the weld seam designs used (preferably butt weld joints) with reference to the notch fall lines of the applicable calculation regulations
• ∘ enables a reduction in the sheet thicknesses used for the outer sheet metal by means of an arrangement of the integrated or integral stiffening elements that is optimized for the stresses and strains
• ∘ enables the optimal use of modern thermal joining processes by minimizing the interruptions and minimizing the change of direction in the joining process of the wall modules
• ∘ enables the optimal use of modern cold forming processes such as roll profiling to manufacture the wall modules
• ∘ the overall system of the properties mentioned enables a high degree of automation of the entire manufacturing process for the wall modules and good accessibility for the usual corrosion protection measures

• 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.

A wall module according to the invention for a component such as a side wall, front wall, roof or the like of a car body of a rail vehicle consists of:

• a section of outer sheet metal with an inner surface which is intended to point in the car body in the direction of the interior of the car,
• a number of linear stiffening elements which extend essentially parallel to one another and along the section of the outer sheet metal and protrude beyond the inner surface of the section of the outer sheet metal, and
• Frame girders, which extend essentially parallel to one another, perpendicular to the stiffening elements and parallel to the section of the outer sheet metal and are firmly connected to the section of the outer sheet metal. As a result, the outer sheet metal, the stiffening elements and the framework girders are connected to one another in such a way that they can safely withstand the compressive, tensile and shear forces introduced into the wall module, and are designed in such a way that
• the stiffening elements extend uninterruptedly over the area of several framework girders and are an integral or integrated part of the section of the outer sheet metal,
• the frame girders have shaped notches at the points of intersection with the stiffening elements, which accommodate the continuous stiffening elements.

The section of the outer sheet metal can have a flat or curved outer surface and a constant or variable sheet metal thickness in a direction running transversely to the stiffening elements, and the stiffening elements can in particular each consist of a web profile with a hollow body profile arranged on it. The wall module according to the invention is characterized in that some or all of the form notches have a shape that, after positioning the framework girders to the section of the outer sheet metal with the stiffening elements in cooperation with the stiffening elements of the outer sheet metal, even without the material connection, a form-fitting temporary self-fixing of the frame girders relative to the Create a section of the outer sheet metal with the stiffening elements.

An integral component of the outer sheet metal is to be understood as a component manufactured in one piece with the outer sheet metal. For example, one or more of the stiffening elements can preferably be formed by means of a primary forming process or a forming process Cold forming, be made as an integral part of the outer sheet metal. In contrast, an integrated component of the outer sheet metal is to be understood as a component that has been formed separately and then joined to the outer sheet metal. For example, one or more of the stiffening elements can be integrated into the outer sheet metal by means of a thermal joining process.

The section of the outer sheet metal of the wall module can consist of one or more wall segments, each with a transverse extent and a longitudinal extent larger in relation to the transverse extent, which each comprise one or more integrated or integral stiffening elements that extend along the longitudinal extent and parallel to the inner surface of the 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 framework supports can contain one or more of the shaped notches, which are designed in such a way that after the mechanical assembly of the framework supports with the stiffening elements, the framework supports contact the outer sheet metal over essentially their entire length or are positioned at a defined distance. This facilitates the subsequent joining of the framework girders with the outer sheet metal.

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

In a first embodiment of the wall segment, the strip-shaped section on the one hand and the web profile and the hollow body profile on the other hand are produced separately and joined to one another by a material-locking joining process. There is the possibility that the The web profile and the hollow body profile are produced separately and joined to one another by a material-locking joining process. For example, the web profile and the hollow body profile can be joined to one another by means of laser or laser hybrid welding. The web profile and hollow body profile can, however, also be produced in one piece, for example by extrusion. In addition, they can have locally variable sheet thicknesses.

In a second embodiment of the wall segment, the strip-shaped section, the web profile and the hollow body profile are produced in one piece as a strip profile. In particular, they can be produced as an originally formed strip profile. Roll profiling, for example, can be used for the primary shaping. In this embodiment, too, the web profile and the hollow body profile can have locally variable sheet metal thicknesses. A gap in the web profile that can be traced back to the original shaping can be closed with a gap corrosion-preventing material, in particular by a material-locking joining method, preferably by a laser welding method or laser soldering method, and preferably filled with the surface on the outer surface of the outer sheet metal.

A car body component according to the invention for a rail vehicle consists of one or more of the wall modules according to the invention. Recesses such as window cutouts, door cutouts, media ducts or the like can be cut out in it with a high degree of accuracy of fit. In these recesses, reinforcement profiles can run all the way around, preferably integrally bonded by laser or laser hybrid welding and joined as a T-joint on the inside of the recesses. In addition, in other wall areas in which particularly high stresses have to be endured, additional reinforcement profiles designed depending on the load and the installation situation, such as door pillars or cove supports, can 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 car body component comprises the steps:

• Manufacture of at least a portion of the outer sheet metal from wall segments according to the invention and inserting and fixing the External sheeting in a holding device in such a way that the stiffening elements are freely accessible for positioning the framework girders,
• Production of the framework girders with the shaped notches and positioning of the framework girders for the outer sheet metal by inserting them into the holding device,
• mechanical joining of the framework girders with the stiffening elements in such a way that the framework girders are positively positioned on the stiffening elements or fixed in a resiliently force-locking manner, with the webs of the framework girders coming into contact with the outer sheet metal or being positioned at a defined distance from the outer sheet metal,
• thermal joining of the framework girders with the outer sheet metal by means of one or more thermal joining processes and
• If necessary, production of the cutouts for windows, doors, media ducts and the like in a wall module after joining the framework girders with the outer sheet metal by means of a thermal and / or machining separation process and mechanical joining of the reinforcement profiles in the cutouts with the wall module in a holding device and then thermally Joining the arrangement by means of one or more thermal joining processes.

The method according to the invention is characterized in that some or all of the form notches have a shape which, after the stiffening elements of the section of the outer sheet metal has been inserted into the form notches of the webs of the frame supports and before the thermal joining in cooperation with the stiffening elements of the outer sheet metal, a form-fitting or force-fitting Fix the frame girders relative to the section of the outer sheet metal with the stiffening elements.

In addition, the method can also include the production of the first stage of a corrosion protection treatment (base coat) of the component including the cavity preservation of the stiffening elements.

The production of the outer sheet metal can essentially take place by the uninterrupted joining of wall segments that extend over the entire length of the car body component.

The joining of the outer sheet metal with the framework girders to form a wall module can take place through the form-fitting positioning and / or force-fitting fixing without additional clamping devices for fixing the frame girders on the outer sheet metal during the thermal joining process. The framework formed by the framework girders consists only of the framework girders without additional fan-like arranged longitudinal profiles for stiffening the outer sheet metal.

A car body according to the invention for a rail vehicle comprises at least one car body component according to the invention. A car body for a rail vehicle produced according to this invention therefore has the feature that the side walls or areas of the side walls, the end walls or areas of the end walls, the roof or a region of the roof are made with wall modules. The wall modules include in particular the design of the outer sheet metal from wall segments with integrated or integral stiffening elements that are guided without interruption through the framework, the framework design essentially without the use of additional longitudinal profiles to stiffen the external sheet and the feature of self-positioning and, if necessary, the temporary self-fixing of the framework via the Stiffening elements of the outer sheet metal. It goes without saying, however, that further reinforcement profiles can be arranged in wall areas in which particularly high stresses can occur, e.g. in the area of cutouts for windows, doors, media ducts and the like.

The components produced according to the invention such as side wall, end wall, roof or the like offer the advantage that they are with a high dimensional accuracy and significantly lower flatness deviations compared to the previously known manufacturing and construction processes and their design enables the optimal use of modern manufacturing and thermal joining processes, in particular roll profiling, laser cutting and laser welding. The possibility of producing wall modules which extend over the entire length (for example of a side wall or a roof) or width (for example of an end wall) of a component for a car body has proven to be particularly advantageous. If separately manufactured stiffening elements are to be integrated into the outer sheet metal, long, uninterrupted weld seams and (particularly advantageous when using laser welding processes) several welding devices can work in parallel at the same time. When using external sheet metal with integral stiffening elements, longitudinal seams are essentially only required for joining the thin-sheet strip profiles. The strip profile used here is particularly suitable for the roll profiling manufacturing process.

From a manufacturing point of view, it can be a particular advantage to make necessary cutouts for windows, doors, media ducts and the like in a wall module only after the framework supports have been joined to the outer sheet metal by means of a thermal and / or cutting process.

The invention enables, in particular through the adapted arrangement of the integrated or integral stiffening elements of the outer sheet metal, comparable structural mechanical properties with a reduced sheet metal thickness compared to the previously known construction methods.

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 requires a significantly lower device and joining time compared to the previously known production methods and construction methods.

The use of wall modules according to the invention allows a high degree of automation of the entire manufacturing process of the wall modules compared to the previously known manufacturing methods and construction methods.

Car bodies for rail vehicles must be designed for a long service life, e.g. for 30 or 35 years. That is why their corrosion protection is of great importance. The design of the components according to the invention and their arrangement have good accessibility for common corrosion protection measures. If components are manufactured by roll profiling, filling in the gaps between them prevents crevice corrosion. The cavity, which is unavoidable in hollow profiles, is also easily accessible to conventional cavity preservation measures.

A construction of the stiffening elements according to the invention also has particular advantages for the interior construction of the car bodies. While it is customary with the car bodies manufactured according to the state of the art, a large number of additional fasteners are used for the attachment of a thermally and acoustically effective inner insulation and / or for the attachment of media lines, partition walls, luggage storage devices, lighting and air conditioning devices and wall cladding, etc. welding can be largely or completely dispensed with in the design of a car body according to the invention if fastening means (clamp elements) are used for the connection of said interior fittings, which are designed in such a way that they can be connected to the stiffening elements in a form-fitting and / or force-fitting manner.

Due to the design according to the invention and the possible high proportion of cold forming in the manufacturing process, a minimization of the heat input acting on the outer sheet metal, the resulting distortion and the corrective measures and manufacturing time required to eliminate or reduce it can be achieved. At the same time, the solution according to the invention enables the structural optimization of the components with regard to the necessary material thicknesses and the spatial requirements (wider or closer spaced) Distribution of the stiffening elements, which, compared to the arrangements and methods known from the prior art, leads to significant savings in material and weight as well as significant savings in operating energy over the life of a rail vehicle with a car body designed according to the invention.

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 emerge from the following description of exemplary embodiments with reference to the accompanying figures.

Figure 1

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

Figure 2

shows an isometric detailed representation of a section of the wall module from Figure 1 .

Figures 3A-E

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

Figure 4

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

Figure 5

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

Figure 6

shows an embodiment of the self-positioning of a frame support in the wall module Figure 1 .

Figure 7

shows an alternative embodiment of the self-positioning of a frame support with self-fixing.

Figure 8

shows another alternative embodiment of the self-positioning of a frame support with self-fixing.

Figure 9

shows an isometric view of a side wall module.

Figure 10

Figure 3 shows an isometric view of a sidewall.

Figure 11

shows an exemplary section through the side wall Figure 10 .

Figure 1 shows an isometric representation of an exemplary embodiment for a wall module 1 designed according to the invention for a rail vehicle, and Figure 2 shows an enlarged section Figure 1 . The wall module 1 consists of the outer sheet metal 2 with integrated or integral stiffening elements 3 and a framework of ribbed girders 4 arranged at certain intervals Wall module 1 manages without a fan-like framework with a large number of additional horizontal stiffening profiles.

The wall module 1 is constructed from a plurality of wall segments 11, 11 ′, each of which contains a strip-shaped segment 2 a of the outer metal sheet 2. In the illustrated wall module 1, different wall segments 11 and 11 'are present. The wall segments 11 each have a longitudinal dimension L and a transverse dimension Q, the longitudinal dimension L being greater than the transverse dimension Q. In each wall segment 11, a stiffening element 3 is integrated or integrally formed, which extends linearly along the longitudinal extent L of the wall segment 11 and protrudes over the inner surface 22 of the outer metal sheet 2. Each stiffening element 3 is guided through the framework girders 4 without interruption. This in Figure 1 The wall element 11 ′ to be recognized has a greater transverse extent in comparison to the wall elements 11. Besides, it is with a plurality of Stiffening elements 3 which run parallel to one another, are integrated or integrally formed, extend longitudinally and protrude beyond the inner surface 22 of the outer metal sheet 2. The segments 2a of the outer sheet metal 2 and thus the wall segments 11, 11 'are welded to one another along linear weld seams 21, for example by means of laser or laser hybrid welding.

Each stiffening element 3 comprises a web profile 5 which is integrated or integrally formed with the outer metal sheet 2 and a hollow body profile 6 arranged at the end of the web profile 5 remote from the outer metal sheet 2 Figures 3A-E show various design options for the hollow body profile 6. In general, the hollow body profile 6 can have 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 design of a wall segment 11. A section from the strip-shaped segment 2a of the outer sheet metal 2 and an integrated stiffening element 3a can be seen. The stiffening element 3a runs uninterrupted over the entire longitudinal extent L of the wall segment and in the present example consists of a web profile 5 welded to the strip-shaped segment 2a of the outer sheet metal 2 along a weld 14 and a hollow body profile 6 welded to the web profile 5 the strip-shaped segment 2a of the outer sheet metal 2 takes place in the present example by means of laser welding. It is particularly advantageous that the welded connections with the stiffening elements 3 a running uninterrupted over the entire length of a wall segment 11 can be produced by uninterrupted weld seams.

FIG.5 shows an alternative example for the design of the wall segment 11. As in FIG Figure 4 a section from the strip-shaped segment 2a of the outer sheet metal 2 and a stiffening element 3b can be seen. In contrast to the in Figure 4 The illustrated embodiment of the wall element 11 is that In the present embodiment, the stiffening element 3b is formed integrally with the strip-shaped segment 2a of the outer metal sheet 2. The hollow profile 6 has an almost completely circular cross section. In the area of the connection of the hollow profile 6 to the web profile 5, there is a bulge 25 of the hollow profile 6 in the direction of the web profile. As a result, an increased elasticity of the hollow profile 6 is achieved in the case of forces acting on the hollow profile 6 within the cross-sectional area.

In the Figure 5 The special shape shown of the web profile 5, the cylindrical hollow profile 6 and the strip profile 2a is preferably produced by roll profiling. The gap 12 in the area of the web profile 5 can be filled at least on the outer surface 24 of the strip-shaped segment 2a of the outer sheet metal 2. It is particularly advantageous in terms of avoiding corrosion if the gap 12 is closed over its entire gap length SL. The filling on the outer surface 24 and the closing of the gap 12 are preferably carried out by a material-locking joining process, preferably by means of laser soldering or gluing or by another welding process in conjunction with a material that prevents crevice corrosion.

FIG.6 shows an embodiment of a self-positioning of a framework 4 on the outer sheet metal 2 via the integrated or integral stiffening element 3. be a curve corresponding to the curvature. For self-positioning, the stiffening element 3 is inserted into a shaped notch 7 in the web 8 of the frame support 4. The shaped notch 7 has an end section 7 a, the cross section of which is essentially complementary to the cross section of the hollow profile 6. The end section 7a is separated from an insertion section 7b, the opening width of which is slightly larger than the diameter of the hollow profile 6.

FIG. 7th shows an embodiment of the self-positioning of a frame support 4 on the outer sheet metal 2 with temporary self-fixing, in which a Temporary self-fixing by means of form-fitting clamping via an integral stiffening element 3b and complementary to the integral stiffening element 3b arranged at least partially form-fitting to the hollow profile shaped notch 7 in the web 8 of the frame support 4 takes place. The shaped notch 7 has an end section 7 a, the cross section of which is essentially complementary to the cross section of the hollow profile 6. The end section 7a is separated from an insertion section 7b, the opening width of which is slightly larger than the diameter of the hollow profile 6, by a latch section 7c, the opening width of which is slightly smaller than the diameter of the hollow profile 6 due to clamping lugs 10 arranged on both sides. When inserting the stiffening element 3 into the shaped notch 7, the hollow profile is compressed by the clamping lugs 10 when it passes the pawl section 7c. After passing the pawl section 7c, the hollow profile 6 expands again in the end section 7a due to its elasticity, so that the hollow profile 6 is positively fixed in the end section 7a by means of the pawl section 7c. The opening width of the clamping lugs 10 is chosen so that when the frame support 4 is clamped onto the stiffening element 3b, only elastic, but no or only a slight plastic deformation of the hollow body profile 6 occurs without the resilient frictional connection being canceled. For the production of the form notches 7, irrespective of the specific design of the form notches 7, laser cutting should preferably be used, since the required high accuracy of shape and fit of the components can be achieved in this way.

FIG.8 shows an alternative embodiment of the self-positioning of a frame support 4 on the outer sheet metal 2 with temporary self-fixation. While in the in Figure 7 If a bilateral arrangement of clamping lugs 10 in the pawl section 7c is used, in the present embodiment there is a temporary self-fixation by a pairing of asymmetrical shaped notches 7. In a pair of asymmetrical mold notches 7, each mold notch has only one pawl section 7c, the pawl sections 7c in the two mold notches 7 of the pair different sides of the shaped notch 7 are arranged so that they can be converted into one another by an axis mirroring. In other words, in a pair of shaped notches 7, the respective pawl sections 7c are oriented differently. The pairs of shaped notches 7 are distributed over the respective frame support 4, the shaped notches 7 of a pair of shaped notches 7 not necessarily having to be arranged next to one another. The elastic clamping of the integrated stiffening element 3 in the frame support 4 is achieved by the interaction of the latch sections 7c of a pair of shaped notches 7. Although the shaped notches 7 in the present exemplary embodiment can be converted into one another by mirroring their axes, this configuration is not absolutely necessary. It is only essential that the two shaped notches 7 of a pair generate an oppositely acting clamping force via the spring action of the web profile 5 through the asymmetrical and opposite, but not necessarily mirrored, arrangement of the pawl section 7c in its area laterally encompassing the hollow profile, so that the shaped notches 7 of the pair can bring about a form fit with the associated stiffening elements 3. Said asymmetry is chosen so that when the framework 4 is clamped onto the stiffening element 3a, only elastic or no failure-promoting plastic deformation of the web profile 5 and the hollow body profile 6 occurs, but the resilient frictional connection is provided. No voltage is permitted after clamping.

FIG.9 shows the isometric representation of a side wall module 13 in the joining position of the framework support 4 to the outer sheet metal 2 with the integrated or integral stiffening elements 3. It can be advantageous to elastically tension the framework support 4 when positioned on the outer sheet metal 2 by means of a device so that Spread the clamping lugs of the shaped notches so that they can be locked onto the stiffening elements 3 associated with the outer sheet metal 2 without increased joining forces. After the clamping lugs have clicked into place, the joining process between the Outer sheet metal 2 and the webs of the framework girders 4 are preferably carried out as a T-joint connection by means of laser or laser hybrid welding 14.

FIG.10 shows the isometric view of a car body component designed as a side wall 17 in the joining position, consisting of a side wall module 13 with cutouts 26, 27 for windows, doors, media ducts and the like made in the side wall module 13 by means of a thermal and / or machining separation process after joining the framework girders 4 as well as In the area of cutouts 26, 27 for windows, doors, media ducts and the like, thermally joined reinforcement profiles 18, door pillars 19 and the cove girder 20 for local stiffening, preferably the thermal cutting process laser cutting or a mechanical cutting process should be used , since the required high accuracy of shape and fit of the components can be achieved in this way.

FIG.11 shows an exemplary section through the representation of the component side wall 17 in the joint of the side wall module 13 with the T-joint-shaped circumferential reinforcement profile 18, the entire contact surface being joined in a materially bonded manner, preferably by means of a 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 car body component can be manufactured by performing the following steps:

• Production of at least a section of the outer sheet metal 2 from wall segments 11,
• Inserting and fixing the outer sheet metal 2 in a holding device in such a way that the stiffening elements 3 are freely accessible for positioning the framework girders 4,
• Production of the framework girders 4 with the shaped notches 7 and positioning of the framework girders 4 in relation to the outer sheet metal 2 by inserting them into the holding device,
• mechanical joining of the framework girders 4 with the stiffening elements 3 in such a way that the framework girders 4 are positively positioned on the stiffening elements 3 or are resiliently non-positively fixed, their webs 8 coming into contact with the outer sheet metal 2 or being positioned at a defined distance from the outer sheet metal 2,
• thermal joining of the framework girders 4 with the outer sheet metal 2 by means of one or more thermal joining processes and
• If necessary, production of the cutouts 26, 27 for windows, doors, media ducts and the like in a wall module after joining the framework girders 4 to the outer sheet metal 2 by means of a thermal and / or machining 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 processes.

This can be followed by the production of the first stage of a corrosion protection treatment (primer coat) of the component including the cavity preservation of the stiffening elements.

The production of the outer sheet metal 2 can essentially take place by the uninterrupted joining of wall segments 11 which extend over the entire length of the car body component.

As part of the process, the joining of the outer sheet metal 2 with the framework girders 4 to form a wall module 1 by positive positioning and / or frictional fixing without additional clamping devices to fix the frame girders 4 on the outer sheet metal during the thermal joining process. The framework formed by the framework girders 4 consists only of the framework girders 4 without additional longitudinal profiles arranged in a fan-like manner for stiffening the outer sheet metal 2.

List of reference symbols:

1

Wall module

2

Outer cladding (a: strip-shaped section)

3

Stiffening element (a: integrated, b: integral)

4th

Framework

5

Web profile

6th

Hollow body profile

7th

Form notch

8th

web

9

Contact contour

10

Clamping nose

11

Wall segment

12th

gap

13th

Sidewall module

14th

Laser or laser hybrid weld seam

17th

Side wall

18th

Reinforcement profiles

19th

Door pillars

20th

Cove support

21

Weld

22nd

Inner surface

23

Profile opening

24

Exterior surface

25th

bulge

26th

Cutout

27

Cutout

Claims (11)

1. Wall module for a component of a carriage body of a rail vehicle, composed of:

   - a portion of an outer sheet-metal panelling (2) having an inner surface (22),

   - a number of linear stiffening elements (3) which extend substantially parallel to one another, and also along the portion of the outer sheet-metal panelling (2), and protrude beyond the inner surface (22) of the portion of the outer sheet-metal panelling (2), and

   - framework structure members (4) which extend substantially parallel to one another, perpendicular to the stiffening elements (3) and parallel to the portion of the outer sheet-metal panelling (2) and are connected to the portion of the outer sheet-metal panelling (2) in a materially bonded manner,

   wherein

   - the stiffening elements (3) extend beyond the region of a plurality of framework structure members (4) in an interruption-free manner and are an integral or integrated constituent part of the portion of the outer sheet-metal panelling (2),

   - the framework structure members (4) have formed notches (7) at the points of intersection with the stiffening elements (3), said formed notches receiving the stiffening elements (3) passing through,

   wherein

   - some or all of the formed notches (7) have a form which, after positioning of the framework structure members (4) with respect to the portion of the outer sheet-metal panelling (2) having the stiffening elements (3), in interaction with the stiffening elements (3) of the outer sheet-metal panelling (2), brings about a form-fitting temporary self-fixing of the framework structure members (4) relative to the portion of the outer sheet-metal panelling (2) having the stiffening elements (3), even without the materially bonded connection,

   characterized in that each stiffening element (3) comprises a web profile (5) which is formed in an integrated or integral manner with the outer sheet-metal panelling (2) and a hollow body profile (6) which is arranged at that end of the web profile (5) which is remote from the outer sheet-metal panelling (2), wherein the hollow body profile (6) can be brought into engagement with the formed notch (7), and wherein the form-fitting temporary self-fixing is formed by interaction of a notch portion (7c) of the formed notch (7) with the hollow body profile (6) .
2. Wall module according to Claim 1, characterized in that the portion of the outer sheet-metal panelling (2) of the wall module is composed of one or more wall segments (11) which each have a transverse extent (Q) and a longitudinal extent (L) that is greater in relation to the transverse extent (Q) and which each comprise one or more integrated or integral stiffening elements (3) which extend along the longitudinal extent (L) and parallel to the inner surface (22) of the wall module.
3. Wall module according to Claim 1 or Claim 2, characterized in that the framework structure members (4) contain one or more of the formed notches (7) which are configured in such a way that, after the framework structure members (4) and the stiffening elements (3) have been mechanically joined together, the framework structure members (4) bear against the outer sheet-metal panelling (2) in a contacting manner over substantially their entire length or are positioned at a defined distance therefrom.
4. Wall module according to one of Claims 1 to 3, characterized in that one or more of the stiffening elements (3) are integrated in the outer sheet-metal panelling (2) by means of a thermal joining process, or in that one or more of the stiffening elements (3) are an integral constituent part of the outer sheet-metal panelling.
5. Carriage body component for a rail vehicle, characterized in that it is composed of one or of a plurality of the wall modules according to Claims 1 to 4.
6. Carriage body for a rail vehicle, characterized in that it contains at least one carriage body component according to Claim 5.
7. Method for producing a carriage body component according to Claim 5, having the work steps of:

   - providing at least one portion of the outer sheet-metal panelling (2) with a number of linear stiffening elements (3) which extend substantially parallel to one another, and also along the portion of the outer sheet-metal panelling (2), and protrude beyond the inner surface (22) of the portion of the outer sheet-metal panelling (2), and providing framework structure members (4) having webs (8) in which formed notches (7) are formed,

   - inserting and fixing the portion of the outer sheet-metal panelling (2) in a holding apparatus in such a way that the stiffening elements (3) are freely accessible for the positioning of the framework structure members (4),

   - positioning the framework structure members (4) with respect to the portion of the outer sheet-metal panelling (2) by insertion into the holding apparatus, wherein the stiffening elements (3) of the portion of the outer sheet-metal panelling (2) are introduced into the formed notches (7) of the webs (8) of the framework structure members (4), as a result of which the framework structure members (4) are positioned, and wherein the webs (8) of the framework structure members (4) come to bear against the outer sheet-metal panelling (2) or are positioned at a defined distance from the portion of the outer sheet-metal panelling (2),

   - thermally joining the framework structure members (4) to the portion of the outer sheet-metal panelling (2) by means of one or more thermal joining processes,

   characterized in that

   - some or all of the formed notches (7) have a form which, after the stiffening elements (3) of the portion of the outer sheet-metal panelling (2) have been introduced into the formed notches (7) of the webs (8) of the framework structure members (4) and prior to the thermal joining, in interaction with the stiffening elements (3) of the outer sheet-metal panelling (2), brings about a form-fitting or force-fitting fixing of the framework structure members (4) relative to the portion of the outer sheet-metal panelling (2) having the stiffening elements (3).
8. Method according to Claim 7, in which the provision of the at least one portion of the outer sheet-metal panelling (2) comprises the production of the at least one portion of the outer sheet-metal panelling (2) .
9. Method according to Claim 7, in which the production of the at least one portion of the outer sheet-metal panelling (2) comprises the interruption-free joining of wall segments (11) according to one of Claims 5 to 8, said wall segments extending over the entire length of the carriage body component.
10. Method according to Claim 9, in which the production of the at least one portion of the outer sheet-metal panelling (2) also comprises the production of the wall segments (11) for the at least one portion of the outer sheet-metal panelling (2) by primary forming or by forming of a sheet metal.
11. Method according to one of Claims 7 to 10, characterized in that the thermal joining of the portion of the outer sheet-metal panelling (2) to the framework structure members (4) to form a wall module (1) is effected by way of the form-fitting or force-fitting fixing without additional clamping apparatuses for fixing the framework structure members (4) on the outer sheet-metal panelling during the thermal joining process, and in that the framework structure formed by the framework structure members (4) is composed only of the framework structure members (4) without any additional longitudinal profiles arranged in a fanlike manner for the stiffening of the outer sheet-metal panelling (2).

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