EP3643577B1 - Structure d'enveloppe pour une caisse de véhicule et procédé de fabrication d'une structure d'enveloppe - Google Patents

Structure d'enveloppe pour une caisse de véhicule et procédé de fabrication d'une structure d'enveloppe Download PDF

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Publication number
EP3643577B1
EP3643577B1 EP19204383.4A EP19204383A EP3643577B1 EP 3643577 B1 EP3643577 B1 EP 3643577B1 EP 19204383 A EP19204383 A EP 19204383A EP 3643577 B1 EP3643577 B1 EP 3643577B1
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EP
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Prior art keywords
envelope structure
structure element
receptacle
extension
wall
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Active
Application number
EP19204383.4A
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German (de)
English (en)
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EP3643577A1 (fr
Inventor
Hendrik Seidler
Sven Uschmann
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Alstom Transportation Germany GmbH
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Bombardier Transportation GmbH
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Publication of EP3643577A1 publication Critical patent/EP3643577A1/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
    • B61D17/041—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures with bodies characterised by use of light metal, e.g. aluminium

Definitions

  • the invention relates to an enveloping structure for a car body for a vehicle, and to a method for producing an enveloping structure.
  • Shell structures of car bodies are often formed from double-layer structures such as double-walled aluminum extrusions.
  • double-walled structure ensures sufficient strength and low weight at the same time.
  • the outer and inner walls of the extruded aluminum profiles are usually connected to one another via struts, which transmit the forces introduced into the enveloping structure or distribute them to the outer and inner walls.
  • the extruded profiles are produced in the required length in an extrusion process and then placed on top of one another and welded together to produce the enveloping structure, i.e. the car body floors, walls and ceilings. Due to the double-walled design of the extruded aluminum profiles, it is necessary for both the outer and inner walls of the extruded profiles placed on top of each other to be connected to one another in a force-conducting manner. This usually takes place via weld seams, which have to be applied both to the outside and to the inside of the car body during manufacture of the car body.
  • a problem in the production of car bodies using welds on both sides is the limited space available in the interior of the car body, which makes automated production of the welds by welding robots more difficult.
  • the welding process that takes place from the inside makes it difficult or prevents possible pre-assembly of components on the enveloping structure elements, on the one hand because of the space required for welding and on the other hand because of the heat input caused by welding, which can damage these components.
  • the DE 10 2007 048 759 A1 and the US 2003/0042293 A1 disclose a method for manufacturing a car body, in which two enveloping structural elements positioned relative to one another in an assembly position together form an access opening through which the inner walls of the enveloping structural elements can be welded to one another from outside the car body. After this Welding the inner walls closes this access opening with a metallic cover. The cover is then welded to the two skin structural elements and forms part of the structure of the skin of the car body.
  • a disadvantage of the known solutions for producing an enveloping structure is the effort required. Additional components must be provided and welded to the skin structure to provide the space required for the inner wall weld.
  • the invention is therefore based on the object of providing an enveloping structure for a car body that is simple and inexpensive to produce.
  • this object is achieved with an enveloping structure according to claim 1 . Furthermore, the object is achieved with a method for producing an enveloping structure according to claim 15. Advantageous developments of the invention are contained in the dependent claims.
  • the solution to the problem for an enveloping structure is that the first enveloping structure element is provided with an extension that extends between the outer wall and the inner wall in an insertion direction, and the second enveloping structure element is provided with a receptacle that opens between the outer wall and the inner wall counter to the insertion direction Insertion of the extension.
  • the extension includes a form-fitting means and the receptacle is filled with a filling material.
  • the extension accommodated in the receptacle and the filling material surrounding the form-fitting means at least in sections thus produce a form-fitting connection.
  • the first shell structure element and the second shell structure element are connected to one another by a weld seam.
  • a second form-fitting connection acting parallel to the weld seam, is produced between the first and second enveloping structure element via the form-fitting means next to the weld seam, only one weld seam and only one welding process is required.
  • a second weld seam can be dispensed with. The welding process can take place from only one side of the enveloping structure, in particular from the outside.
  • the weld seam and the form-fitting connection are preferably arranged at a great distance from one another and/or on opposite sides of a central plane of the enveloping structure.
  • the form-fitting connection is preferably arranged close to an edge region of the enveloping structure, in particular on an outside of the enveloping structure, which faces outwards when the car body is installed.
  • the extension of the first enveloping structure element is first inserted into the receptacle of the second enveloping structure element.
  • the receptacle of the second enveloping structure element is then filled with a filling material that hardens in particular at low temperatures or cold.
  • the first structural envelope element is welded to the second structural envelope element on one side, i.e. from one side. Only one weld seam is preferably produced.
  • Welding of the structural shell elements can take place before or after the filling of the receptacle, with welding of the structural shell elements after the receptacle has been filled and the filling material has hardened being preferred because the structural shell elements are thus already fixed in their final position during the welding process.
  • the hardened filling material finally forms a form fit with the form fit means located on the extension.
  • the enveloping structure according to the invention can be suitable for a car body of a railway vehicle, or for other vehicles such as buses.
  • the extension can have an indentation which extends essentially perpendicularly to the direction of insertion and which forms the form-fitting means.
  • the form-fitting means can be formed by an elevation or a through-opening.
  • the extension can have an undercut into which the filling material can flow. After the extension has been inserted into the receptacle, the filling material can be conveyed into the receptacle under pressure in order to ensure that the filling material completely surrounds or borders the form-fitting means.
  • the filling material can also form a form fit with the receptacle.
  • the receptacle can have a receptacle opening for inserting the extension.
  • the receptacle preferably widens in the insertion direction, starting from the receptacle opening, or the receptacle tapers in the opposite direction to the insertion direction.
  • a filling material that has been poured into the receptacle and has hardened cannot be pushed out through the receptacle opening and forms a form fit with the receptacle.
  • At least one inner wall of the receptacle can be at a distance from the extension or the form-fitting means.
  • the distance ensures that the filling material completely surrounds the form-fitting means and forms an effective form-fitting connection with it.
  • the form-fitting means is at a distance from the inner wall or walls of the receptacle over its entire circumference.
  • the receptacle is designed in such a way that the filling material can be conveyed into the receptacle under pressure.
  • the second enveloping structure element can be provided with a filling opening which penetrates through the outer wall or inner wall of the second enveloping structure element and leads into the receptacle.
  • several filling openings can be provided.
  • the filling openings can preferably be arranged in a transverse direction of the enveloping structure element at the same height as the form-fitting means.
  • the insertion direction in which the extension is inserted into the receptacle runs essentially parallel to the outer wall and/or to the inner wall of the first enveloping structure element.
  • the extension is accommodated in the receptacle when the outer walls and/or inner walls of the enveloping structure elements are aligned with one another.
  • the extension can thus be introduced into the receptacle or positioned in the receptacle by aligning the outer and/or inner walls.
  • the receptacle In order to predominantly compress the filling material in the hardened state and to reduce tensile and shearing forces, the receptacle can widen conically or funnel-shaped starting from the receptacle opening.
  • the receptacle acts as a mold for the filling material.
  • the filling material can thus form a filling body that is conical at least in sections in the hardened state.
  • a tensile force acting on the extension or the form-fitting means can thus continue via the conical surface of the filling body as a compressive force on the inner surface of the receptacle, which is also conical.
  • the filling material can be adhesively bonded to the extension and/or the receptacle.
  • the adhesive connection can be made directly over the filling material, e.g. by using a curing adhesive as the filling material.
  • the enveloping structure is preferably welded on the outside.
  • the respective other side preferably the inside of the enveloping structure, is positively connected via the extension in the first enveloping structure element, the receptacle in the second enveloping structure element and the filling material in the receptacle.
  • the form fit can be produced at least partially via the extension and a receiving opening of the receptacle.
  • the receiving opening, into which the extension can be inserted can have a width that is only slightly larger than the extension, if possible, in order to enable the transmission of force with as little play as possible.
  • the weld seam can be arranged on mutually opposite surfaces of the inner wall or the outer wall of the first structural envelope element and the second structural envelope element. Opposite surfaces of the outer walls of the first and second shell structure element are preferably welded to one another, while opposite surfaces of the inner walls have no weld seams. In this way, the integral connection of the two enveloping structure elements can be produced solely from the outside.
  • the weld seam can be applied to the enveloping structure from the outside in order to be able to provide sufficient space for welding devices or welding robots.
  • the first and/or second enveloping structure element are formed from extruded profiles, in particular aluminum extruded profiles. These can be produced efficiently, while high strength can be achieved with low weight.
  • the first structural shell element including the extension and/or the second structural shell element including the receptacle is formed from an extruded profile.
  • Extension and/or receptacle can correspondingly extend over the entire length of the respective extruded profile.
  • this is preferably designed as a solid profile.
  • a weld pool safety device can be provided.
  • the weld pool backup can preferably be formed by the first or second enveloping structure element and in particular can be part of an aluminum extruded profile.
  • the first or the second enveloping structure element can have an extension which engages behind the weld seam from the inside and which is suitable for forming a weld pool backup.
  • the extension can preferably overlap the parting line between two walls to be welded of the first and second enveloping structure element.
  • a material that hardens at low temperatures is preferably provided as the filling material.
  • the filling material is liquid in a processing state at relatively low temperatures, in particular at temperatures below 300°C, preferably at temperatures below 200°C, most preferably at temperatures below 100°C.
  • the filler material can be liquid in a processing state at temperatures below 40°C.
  • the filling material can be designed to have an adhesive effect in order to adhesively fasten the extension in the receptacle.
  • the extension or the form-fitting means can be held in the receptacle in a form-fitting and adhesive manner.
  • the filling material may comprise a cold-setting plastic such as a thermoset.
  • fibers can be provided in the filling material in order to form a high-tensile fiber composite.
  • a pressure-resistant component can be added, such as sand, in particular quartz sand, ceramic or metal, in order to increase the pressure resistance of the filling material.
  • the filling material can have a component that expands during curing.
  • a rail vehicle according to the invention has one of the above-described embodiments of an enveloping structure according to the invention.
  • the first structural envelope element 2 has an outer wall 4 and an inner wall 5
  • the second structural envelope element 3 has an outer wall 6 and an inner wall 7.
  • Outer walls 4, 6 and inner walls 5, 7 are connected to one another via struts 22, 23, which are connected between outer walls 4, 6 and inner walls 5, 7 transmitted forces occurring.
  • the struts 22, 23 can form a framework structure between the outer and inner walls. You can run horizontally or diagonally in the further course of the shell structure elements 2, 3.
  • the first enveloping structure element 2 and the second enveloping structure element 3 are designed in such a way that they are placed on top of one another or plugged into one another in an assembly position and are aligned by guide surfaces.
  • an extension 8 is provided on the first structural envelope element 2 and a receptacle 9 on the second structural envelope element 3 .
  • the receptacle 9 has a receptacle opening 16 through which the extension 8 can be inserted into the receptacle 9 .
  • the extension 8 is part of the extruded profile from which the first structural envelope element 2 is formed and extends over the entire length of the structural envelope element 2.
  • the receiving opening 16 is correspondingly part of the aluminum extruded profile, from which the second shell structure element 3 is formed, and extends over the entire length of the second shell structure element 3.
  • the width B of the receiving opening 16 is only slightly wider than the width b of the extension 8.
  • the extension 8 therefore acts together with the accommodating opening 16 as a guide for the first enveloping structure element 2 in the second enveloping structure element 3, wherein the guide restricts the movement of the first enveloping structure element 2 relative to the second enveloping structure element 3 in a transverse direction Q.
  • a clearance fit can be provided between the extension 8 and the receiving opening 16 .
  • Support surfaces 17 are provided on the first structural envelope element 2 on both sides of the extension 8
  • support surfaces 18 are provided on the second structural envelope element 3 on both sides of the receiving opening 16.
  • the first structural envelope element 2 can now be moved onto the second structural envelope element 3 until the extension 8 reaches the receptacle 9 and the bearing surfaces 17 come to rest on the bearing surfaces 18 .
  • First and second shell structure element 2, 3 are designed to be welded together.
  • a welding surface 19 for receiving a weld seam is arranged on the outer wall 4 of the first enveloping structure element 2, and a welding surface 20 is arranged on the second enveloping structure element 3.
  • the welding surfaces 19 and 20 run at an angle to the outer walls 4, 6, so that when the enveloping structure elements 2, 3 an externally accessible depression for receiving the welding material is created.
  • the first enveloping structure element 2 also has a weld pool safety device 21, which is used to catch welding material escaping during the welding process.
  • the weld pool backup 21 is part of the first enveloping structure element 2 and is produced with it in one operation using the extrusion process.
  • the weld pool backup 21 extends in the direction of insertion E and, when the enveloping structure is assembled, overlaps the welding joint between the enveloping structure elements 2, 3.
  • a support surface 12 provided on the weld pool backup 21 on the first enveloping structure element 2 is arranged opposite a support surface 13 on the second enveloping structure element 3 when the enveloping structure is assembled.
  • the support surfaces 12, 13, like the extension 8 and the receptacle 9, function as guides and produce a partial positive fit when the enveloping structure is assembled, which defines the position of the enveloping structure elements 2, 3 before establishing a form-fitting or material-fitting relationship in the insertion direction.
  • a filling opening 14 is provided in the inner wall 7 of the second enveloping structure element 3 .
  • the filling opening 14 is used to introduce filling material into the receptacle 9 in order to create a form fit with the first enveloping structure element 2 via the form-fitting means 10 on the extension 8 .
  • the filling material can be supplied under pressure through the opening 14 in order to ensure that the receptacle 9 is completely filled and, in the hardened state of the filling material, that there is a complete form fit with the form-fitting means 10 .
  • the filling material is preferably designed to be cold curable or hardenable at low temperatures in order to avoid additional thermal stress on the second enveloping structure element 3 .
  • FIG. 2 shows a section of an assembled enveloping structure, the enveloping structure elements 2, 3 of which are connected to one another in a form-fitting and material-locking manner according to the invention in order to form an enveloping structure 1.
  • the form fit between the first structural envelope element 2 and the second structural envelope element 3 is achieved via the extension 8 with the form-fit means 10 and the filling material 24 accommodated in the receptacle 9 .
  • the filling material 24 can be conveyed into the receptacle 9 via the filling opening 14 . Because the filling material 24 is fed in under pressure, it is ensured that the form-fitting means 10 is ultimately completely surrounded by the filling material 24 .
  • the filling material 24 can in particular penetrate into the indentation 15 of the form-fitting means 10 . If the filling material 24 then hardens, it is connected in a form-fitting manner to the form-fitting means 10 . At the same time, the filling material 24 in the hardened state is positively connected to the second enveloping structure element 3 via the receptacle 9 .
  • the receptacle 9 tapers upwards, ie counter to the direction of insertion E.
  • Hardened filling material 24 located in the receptacle consequently also forms a form fit with the receptacle 9 and cannot be displaced counter to the direction of insertion. Furthermore, part of the filling material 24 can remain in the filling opening after the filling process. Above the filling material 24 in the filling opening 14 creates a further form fit when the filling material 24 hardens.
  • the filling material 24 can have an adhesive effect and the first structural envelope element 2 via the extension 8 adhesively connect to the second shell structure element 3 .
  • the two outer walls 4, 6 of the shell structure elements 2, 3 are connected to one another by a weld seam 11.
  • the weld seam 11 forms a material connection that acts parallel to the form-fitting connection 25 described above.
  • the weld seam 11 and the form-fitting connection 25 together form a sufficiently rigid connection that enables an envelope structure 1 to be constructed with high rigidity.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Connection Of Plates (AREA)

Claims (15)

  1. Structure d'enveloppe (1) pour une carrosserie pour un véhicule automobile, comportant un premier élément de structure d'enveloppe (2) et un deuxième élément de structure d'enveloppe (3), dans laquelle
    - le premier élément de structure d'enveloppe (2) et le deuxième élément de structure d'enveloppe (3) comportent respectivement une paroi externe (4, 6) et une paroi interne (5, 7),
    - le premier élément de structure d'enveloppe (2) est pourvu d'un prolongement (8) s'étendant entre la paroi externe (4) et la paroi interne (5) dans un sens d'insertion (E),
    - le deuxième élément de structure d'enveloppe (3) comporte un logement (9) débouchant entre la paroi externe (6) et la paroi interne (7) à l'opposé du sens d'insertion (E) et permettant d'insérer le prolongement (8),
    - le prolongement (8) comprend un moyen de liaison par complémentarité de forme (10),
    - le logement (9) est rempli d'un matériau de remplissage (24),
    - une liaison par complémentarité de forme est produite par le prolongement (8) reçu dans le logement (9) et le matériau de remplissage (24) entourant au moins par zones le moyen de liaison par complémentarité de forme (10),
    - le premier élément de structure d'enveloppe (2) et le deuxième élément de structure d'enveloppe (3) sont reliés l'un à l'autre par un cordon de soudure (11).
  2. Structure d'enveloppe (1) selon la revendication 1, dans laquelle le cordon de soudure (11) est disposé sur des surfaces opposées de la paroi interne (5, 7) ou de la paroi externe (4, 6) du premier élément de structure d'enveloppe (2) et du deuxième élément de structure d'enveloppe (3).
  3. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le cordon de soudure (11) est appliqué sur la structure d'enveloppe (1) depuis l'extérieur.
  4. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le premier ou le deuxième élément de structure d'enveloppe (2, 3) comporte un prolongement, lequel vient en prise par l'arrière avec le cordon de soudure (11) depuis l'intérieur et lequel est conçu pour former un dispositif de sécurité pour bain de soudure.
  5. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le premier et/ou le deuxième éléments de structure d'enveloppe (2, 3) sont formés à partir de profilés extrudés.
  6. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le premier élément de structure d'enveloppe (2) y compris le prolongement (8) et/ou le deuxième élément de structure d'enveloppe (3) y compris le logement sont formés à partir d'un profilé extrudé.
  7. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le logement (9) s'effile dans le sens opposé au sens d'insertion (E).
  8. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle au moins une paroi interne (5) du logement est espacée du moyen de liaison par complémentarité de forme (10).
  9. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le deuxième élément de structure d'enveloppe (3) est pourvu d'une ouverture de remplissage (14), laquelle traverse la paroi externe (6) ou la paroi interne (7) du deuxième élément de structure d'enveloppe (3) et débouche dans le logement (9).
  10. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le sens d'insertion (E) s'étend sensiblement parallèlement à la paroi externe (4) et/ou à la paroi interne (5) du premier élément de structure d'enveloppe (2).
  11. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le prolongement (8) est reçu dans le logement (9) lorsque les parois externes (4, 6) et/ou les parois internes (5, 7) des éléments de structure d'enveloppe (2, 3) sont alignées les unes avec les autres.
  12. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le prolongement (8) comporte une rainure (15), laquelle s'étend sensiblement perpendiculairement au sens d'insertion (E).
  13. Structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, dans laquelle le matériau de remplissage (24) comprend une matière thermodurcissable.
  14. Structure d'enveloppe (1) selon la revendication 13, dans laquelle une liaison par complémentarité de forme entre le premier élément de structure d'enveloppe (2) et le deuxième élément de structure d'enveloppe (3) est réalisée par l'intermédiaire du matériau de remplissage (24) à l'état durci.
  15. Procédé de réalisation d'une structure d'enveloppe (1) selon l'une quelconque des revendications précédentes, comprenant les étapes suivantes :
    a) la fourniture d'un premier et d'un deuxième éléments de structure d'enveloppe (2, 3) ;
    b) puis l'insertion du prolongement (8) du premier élément de structure d'enveloppe (2) dans le logement (9) du deuxième élément de structure d'enveloppe (3) ;
    c) puis le remplissage du logement du deuxième élément de structure d'enveloppe (3) avec un matériau de remplissage (24), en particulier durcissant à froid ;
    d) puis le durcissement du matériau de remplissage (24) ;
    e) le soudage unilatéral du premier élément de structure d'enveloppe (2) au deuxième élément de structure d'enveloppe (3).
EP19204383.4A 2018-10-26 2019-10-21 Structure d'enveloppe pour une caisse de véhicule et procédé de fabrication d'une structure d'enveloppe Active EP3643577B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102018126814.9A DE102018126814A1 (de) 2018-10-26 2018-10-26 Hüllstruktur für einen Wagenkasten und Verfahren zur Herstellung einer Hüllstruktur

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EP3643577A1 EP3643577A1 (fr) 2020-04-29
EP3643577B1 true EP3643577B1 (fr) 2022-06-15

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DE (1) DE102018126814A1 (fr)

Family Cites Families (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11311218A (ja) * 1998-04-27 1999-11-09 Showa Alum Corp 中空パネルの結合構造
JP3761736B2 (ja) * 1999-02-16 2006-03-29 株式会社日立製作所 摩擦撹拌接合方法
JP3289779B2 (ja) * 1999-07-30 2002-06-10 日本軽金属株式会社 中空パネル構造体の製造方法及びその製造用中空押出形材
DE19937375C2 (de) * 1999-08-07 2003-09-18 Daimler Chrysler Ag Konstruktionsbauteil und Verfahren zu dessen Herstellung
JP2002178169A (ja) * 2000-12-14 2002-06-25 Kobe Steel Ltd 輸送機用構造体及びその製造方法
DE10101362A1 (de) * 2001-01-13 2002-07-18 Siemens Duewag Gmbh Großräumiges Fahrzeug, insbesondere Schienenfahrzeug
JP3751237B2 (ja) 2001-09-03 2006-03-01 株式会社日立製作所 摩擦攪拌接合用接続材
DE102005048001B4 (de) * 2005-10-06 2007-06-14 Euro-Composites S.A., Zone Industrielle Verbindungselement
FR2907040B1 (fr) 2006-10-13 2009-06-26 Alstom Transport Sa Procede d'assemblage d'une structure comportant un exterieur et un interieur constituee d'une pluralite d'elements a double peau,telle qu'une caisse de vehicule ferroviaire,et structure obtenue.
DE102007035772B4 (de) * 2007-07-27 2014-10-09 Siemens Aktiengesellschaft Wagenkasten für ein Schienenfahrzeug
JP5649465B2 (ja) * 2011-01-18 2015-01-07 日立機材株式会社 パネル構造
DE102011088509B4 (de) * 2011-12-14 2014-12-04 Siemens Aktiengesellschaft Schienenfahrzeugwagenkasten und Verfahren zu dessen Herstellung
DE102015201660A1 (de) * 2015-01-30 2016-08-04 Siemens Aktiengesellschaft Wandanordnung für ein Fahrzeug
FR3054192B1 (fr) 2016-07-19 2019-06-28 Alstom Transport Technologies Procede d'assemblage de vehicule ferroviaire

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EP3643577A1 (fr) 2020-04-29

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