RU2567098C2 - Fabrication of hopper car roof - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to railway transport, particularly, to production of holler car roof. Hopper car roof is made of composite as a self-bearing shell. Proposed method consists in fabrication of forming elements of crosswise structural frames, end ribs, lower roof strapping belt and die with ledges for making the loading hatch openings and guides for installing of forming elements of crosswise structural frames and end ribs. Filler player is placed in the die to form the lining, crosswise structural frames and end ribs. Lower structural strapping belt forming element is placed and laid are filler layers for forming the elements of lower structural strapping belt. Clamp is arranged along perimeter of said die to form the roof lining part to enter the holler car. Layers that form crosswise structural frame linins are laid to infuse glass finer into the die for its polymerisation.

EFFECT: enhanced performances, higher structural strength.

8 cl, 8 dwg

Description

FIELD OF THE INVENTION

The present invention relates to railway transport, in particular to a method for manufacturing the roof of a hopper car.

State of the art

The design of a hopper car designed for transportation of bulk cargoes (sand, gravel, etc.) by rail is quite traditional. Typically, the body of such a hopper car is covered with a roof in the form of an upward convex gutter made of individual steel sheets (see, for example, US Patent No. 4,370,058, publ. 05.22.1983). This raises the problem of joining such individual sheets, as well as protecting the steel from rust, which may occur due to atmospheric humidity.

In US patent No. 6367391 (publ. 09.04.2002) disclosed the roof of the hopper car, made of two layers of reinforced plastic with foam filler between them. There are no loading openings in this roof, and the implementation of the entire gutter-shaped roof of two layers of reinforced plastic with foam filler between them makes it more expensive to manufacture such a roof and make it heavier.

The closest analogue to the present invention can be considered US patent No. 5988074 (publ. 11/23/1999), which describes a composite roof for a railway carriage, which is made almost flat from layers of fiber-reinforced plastic and has rectangular openings. This design is quite technologically advanced, but has a low strength.

Disclosure of invention

Thus, the aim of the present invention is to expand the arsenal of technical means and increase the strength of the structure.

To achieve this technical result, the present invention provides a method for manufacturing the roof of a hopper car made as a self-supporting shell in the form of a convex upward chute with end walls, a lower force binding belt of a trapezoidal cross section is made along the lower edge of the perimeter of the chute; each of the end walls is provided with at least two end ribs closed in the lower part of the gutter to the lower power binding belt, transverse power frames are installed on the inner side of the gutter at predetermined distances from one another and from the end walls, closed in the lower part of the gutter to the lower a power strapping belt, in the upper part of the gutter, a predetermined number of holes of loading hatches located between the transverse power frames are made, the method comprising the steps of: prepare from forming elements transverse load-bearing frames, the end edges and lower power banded belt so that each of the forming elements has a thickness of a predetermined portion of the thickness of the manufactured items; a mold is made for subsequent roof manufacturing by infusion, and protrusions are provided in this form for creating openings for loading hatches and guides for installing forming elements of frames and end ribs; at least one layer of at least one filler is laid in the mold to form the roof skin; establish on the guides the manufactured forming elements of the transverse power frames and end ribs; establish the forming element of the lower power strapping belt in the gap provided between the forming elements of the transverse power frames and the casing; lay out filler layers of different orientations on the forming element of the lower power strapping belt, which form the elements of the lower power strapping belt; establish a clamp around the perimeter of the form, forming that part of the roof sheathing that is intended to enter the hopper car during its manufacture; lay out on the appropriate places the layers that form the skin of the frames; and infusing fiberglass into a mold followed by polymerization of the fiberglass.

A feature of the method of the present invention is that at the stage of manufacturing the forming elements of the end ribs: give the forming elements of the end ribs in cross section a U-shaped shape to form an internal cavity; and fill the internal cavity with pouring polyurethane foam.

Another feature of the method of the present invention is that at the stage of installation of the forming elements of the transverse power frames, a vacuum bag is installed in the cavity between the pair of forming elements of each of the transverse power frames.

Another feature of the method of the present invention is that at the stage of laying the fillers to form the roof sheathing, a honeycomb core is laid out next to the protrusions to create openings for the loading hatches.

Another feature of the method of the present invention is that after laying out the layers forming the elements of the lower power binding belt, a profiled U-shaped cross-section silicone insert is installed on these layers to obtain a docking zone of the roof with the hopper car.

Another feature of the method according to the present invention is that before removing the roof from the mold after polymerization is applied to the inner surface of the roof coating that protects against abrasion.

Another feature of the method of the present invention is that the roof is machined after it is removed from the mold at the end of the polymerization.

Finally, another feature of the method of the present invention is that after removing the roof from the mold after polymerization: wear-resistant coating is applied to the surface of the pedestrian zone; install pre-made hinged lids on the holes of the loading hatches; installing at least one prefabricated device for balancing the pressure on the corresponding end wall; attach prefabricated pedestrian fences and stairs; fireproof and paint coatings are applied to the outer surfaces of the roof.

Brief Description of the Drawings

The present invention is further illustrated with reference to the attached drawings, in which the same elements are assigned the same reference position.

FIG. 1 shows a general view of a roof hopper car.

Figure 2 depicts the roof of the hopper car of the present invention in a disassembled form with a partial cutaway.

Figures 3-5 show successive steps for manufacturing a roof of the present invention.

6 illustrates the implementation of the end part of the roof of the present invention.

7 shows a docking of a corner of a roof of the present invention with a hopper car.

Fig. 8 illustrates the fastening of the roof frame of the present invention to the wall of the hopper car.

DETAILED DESCRIPTION OF THE INVENTION

As is obvious from the title of the present invention, the proposed roof is intended for installation on a railway hopper car, i.e. a wagon intended for the transport of bulk goods poured into this wagon from above and unloaded from it by folding the bottom of the wagon. A general view of such a hopper car is shown in FIG. 1, where reference numeral 1 denotes the body of a hopper car, and reference numeral 2 denotes the roof of this hopper car. As can be seen from Figure 1, the roof 2 is made in the form of a convex upward chute with end walls 3. In the upper part of the chute (roof 2), a predetermined number of holes 4 for loading hatches are made. In addition, the upper part of the gutter (roof 2) is preferably (but not necessarily) flat, and pedestrian zones 5 are provided on both sides of the openings 4 of the loading hatches on the flat upper part, each of which is preferably made with a non-slip wear-resistant coating. From the outside (i.e., from the side opposite the holes 4), each pedestrian zone 5 is preferably provided with a fence 6.

As shown in FIG. 2, the openings 4 of the loading hatches are preferably generally rectangular in shape, although they may have fillets in the corners (see pos. 4 in FIG. 3) and are located along the middle of the flat top. Each loading hatch is closed with a corresponding cover 7, which can be folded towards one of the pedestrian zones 5.

Figure 2 shows the transverse power frames 8 installed on the inner side of the gutter (roof 2) at predetermined distances from each other and from the end walls 3. All these transverse power frames 8 are closed in the lower part of the gutter to the lower power strapping belt 9, made along the lower edge of the perimeter of the gutter and partially visible in figure 2 in a section on the lower edge of the gutter. The aforementioned openings 4 for loading hatches are each located between adjacent transverse power frames 8.

In addition, each of the end walls 3 can be equipped with two (or more) end ribs 10 (Fig. 3), closed at the bottom of the trough to the lower power tie belt 9. At least one of the end walls 3 is preferably provided with a decompression device 11 for pressure equalization inside the hopper car with the covers 7 closed during unloading. This decompression device 11 in the simplest case is a hole in the end wall 3, covered from above by a plate bent down (see Figure 3). On one or on both end walls 3, a ladder 12 can be mounted (see Figure 2).

The lower surface around the entire perimeter of the lower power binding belt 9 preferably has an inverted U-shape to prevent rain and snow from entering the car. Figure 4 illustrates the placement of the roof 2 on the body 1 of the car. When installing the roof 2 on the body 1, the inverted U-shape of the lower surface of the lower power strapping belt 9 fits tightly on the strapping of the body 1 (shown in Fig. 4 as a pipe of rectangular cross section).

A preferred fastening of the roof 2 to the body 1 is illustrated in FIG. 5. Each of the transverse power frames 8 has an extension at the end, which when installing the roof 2 on the body 1 of the hopper car enters the corresponding brackets 13 and is fixed with a cotter pin 14 or a bolt with a nut. Brackets 13 for fixing the roof 2 are installed on the inner side of the side walls of the body 1 in place (when installing the roof 2) and are fastened with any suitable fastenings (welding, bolts, etc.).

An important feature of the roof of the present invention is its material, which is used as one or more composite materials. In this case, it is preferable to use fiberglass with a reinforcing filler as a composite material, and the roof 2 is made by infusion. Fiberglass in this case is fiberglass of the ApATEK-STINK brand (TU2296-006-9366864-2008, see certif.org/docs/reestr_tc.xls) with a volume content of reinforcing filler of 50-55%. Reinforcement can be implemented by selecting the appropriate fillers from the product line of fiberglass, commercially available by Selcom S.r.l., or other manufacturers. As a binder, you can use the polyester resin Aropol S604 INF-90 (150) or similar in characteristics.

The use of these materials for the manufacture of fiberglass by infusion provides fiberglass with high strength characteristics, the level of which does not depend significantly on the heat treatment mode and practically does not decrease after thermal humidity aging. At the same time, in the manufacture of roof 2, auxiliary filler in the form of a polyester non-woven material can be used, for example, Lantor Soric® - a polyester non-woven material that is compression resistant and compatible with all standard types of resins (including polyester, vinyl ether, phenol aldehyde and epoxy). This material has a high flat and through permeability, which ensures high-quality impregnation of the power layers. The use of this material can significantly reduce the number of used conductive layer. Lantor Soric® is suitable for all closed forming processes, including infusion and pultrusion. The use of this material as an auxiliary filler gives the casing the necessary rigidity without significantly weighting it.

In the manufacture of pedestrian zones 5, it is possible to use polypropylene honeycomb material, for example, Nidaplast® 8Ri polypropylene honeycomb, which are suitable for closed molding processes such as infusion.

As a preferred technology for the manufacture of roof 2 from composite materials, the technology of vacuum infusion is selected. To minimize the bolt, adhesive and kleebolt zones of the joints, the molding of the shell with the power frame (i.e. with transverse power frames 8, end edges 10 and the lower power strapping belt 9) is performed in a single technological cycle. The manufacture of a self-supporting shell roof 2 is as follows.

First, forming elements are made for the transverse power frames 8, end ribs 10 and the lower force strapping belt 9.

The forming elements of the transverse force frames 8 and the end ribs 10 are thin-walled elements prefabricated by vacuum infusion and having a thickness of about 15-20% of the structural thickness of the transverse force frame and 8-10% of the thickness of the end rib. Those. each of these forming elements has a thickness constituting a predetermined part of the thickness of the manufactured part.

Simultaneously with the manufacture of the above forming elements, or independently of their manufacture (for example, before or after their manufacture), a mold is made for the subsequent manufacture of the roof 2 by infusion, and protrusions are provided in this form for creating openings 4 of the loading hatches and guides for installing the above forming elements transverse power frames 8 and end ribs 10.

One or more layers of one or more fillers are laid in the finished form to form the roof sheath 2. FIG. 6 shows a matrix (form) 15 in which the outer skin layers 16 and the aggregate 17 are laid, which are then closed by the inner skin layers 18 shown on 7. In addition, along the guides of the mold 15, the fabricated forming elements 19 of the transverse power frames are installed and, on the end walls 3, the forming elements of the end ribs (not shown in FIG. 7) are installed. In pedestrian areas, honeycomb can be laid out next to the protrusions, which serve to create holes for 4 loading hatches.

In the gap provided between the layers 16 and 18 (between the casing and the forming elements 19 of the transverse power frames), the forming element 20 of the lower power binding belt is installed, onto which the layers of filler 21 of different orientations (from the already mentioned Lantor Soric® material) are laid, which form the elements of the lower power binding belt 9.

To give rigidity to the forming elements of the end ribs 10, a U-shape is given in cross section to form an internal cavity, which at the time of evacuation can be filled with filling polyurethane foam with a density of about 35 kg / m ³ .

For transverse power frames 8, a molding scheme with an internal vacuum bag can be implemented, which eliminates the use of foam as a filler in the internal cavity and reduces the total weight of the structure.

The profiled silicone insert 22 of a U-shaped cross section (see Fig. 8) can be placed on the elements of the lower power strapping belt 9 to form the geometry of the seat of the lower power strapping belt 9. This insert is prefabricated from block foam with a density of 40 ... 50 kg / m ³ or by pouring components into the appropriate form. Then, a clamp 23 is installed along the perimeter of the form 15, forming that part of the roof sheath 2, which is intended to enter the body 1 of the hopper car in the manufacturing process of this car. Layers 24 are laid out at the appropriate places, which form the casing of the transverse power frames 8 and end ribs 10.

After these operations, fiberglass is infused with mold 15 followed by polymerization.

Before removing the finished roof 2 from the mold 15, upon completion of the polymerization process, a coating can be applied to the inner surfaces of the roof 2 to protect the roof from abrasion. After removing the roof 2 from the mold 15, upon completion of the polymerization process, the roof 2 can be machined to remove the flake. In addition, after removing the roof 2 from form 15 at the end of the polymerization process, a wear-resistant coating is applied to the surface of the pedestrian zone 5.

On the finished roof 2 install pre-made hinged lids 7 on the holes 4 of the loading hatches. On the outer edges of the pedestrian zones 5, pre-made fences 6 of the pedestrian zones are attached, and a ladder 12 is attached to one of the end walls 3. A pre-fabricated device 11 for equalizing the pressure is mounted on the corresponding end wall 3.

If necessary, fireproof and paint coatings are applied to the outer surfaces of the finished roof 2.

Thus, the proposed design of the roof of the hopper car has increased strength, while at the same time being quite technologically advanced in manufacturing. This ensured the expansion of the arsenal of technical means.

The above examples of preferred embodiments of the roof of the hopper car and the method of its manufacture are purely illustrative and in no way limit the scope of legal protection of the present invention, which is determined only by the attached claims taking into account its equivalents.

Claims (8)

1. A method of manufacturing the roof of the hopper car, made as a self-supporting shell in the form of a convex upward chute with end walls, a lower force binding belt of a trapezoidal cross section is made along the lower edge of the perimeter of the said chute; each of said end walls is provided with at least two end ribs closed in the lower part of said trough to said lower power strapping belt, transverse power frames are installed on the inside of said trench at predetermined distances from one another and from said end walls, closed in the lower part of the said trough to the said lower power strapping belt, in the upper part of the said trough, a predetermined number of holes for loading hatches are made, position married between the aforementioned transverse power frames, while the aforementioned method comprises the steps of:
- make the forming elements of the said transverse power frames, end ribs and lower power strapping belt so that each of these forming elements has a thickness that is a predetermined part of the thickness of the manufactured parts;
- make a mold for the subsequent manufacture of the said roof by infusion, and provide in the said form protrusions for creating said openings of loading hatches and guides for installing said forming elements of transverse power frames and end ribs;
at least one layer of at least one filler is laid in said mold to form a skin for said roof;
- establish on the said guides the fabricated forming elements of the transverse power frames and end ribs;
- establish the forming element of the lower power strapping belt in the gap provided between the said forming elements of the transverse power frames and said casing;
- lay out on the said forming element of the lower power strapping belt the filler layers of different orientations, which form the elements of the lower power strapping belt;
- install a clamp around the perimeter of the said shape, forming that part of the skin of the said roof, which is intended to enter the said hopper car during its manufacture;
- lay out in appropriate places the layers that form the skin of the said transverse power frames; and
- carry out the infusion of fiberglass in the aforementioned form, followed by polymerization of the fiberglass. 2. The method according to claim 1, in which at the stage of manufacturing the said forming elements of the end ribs:
- give the said forming elements of the end ribs in cross section a U-shape for the formation of the internal cavity; and
- fill said internal cavity with polyurethane foam. 3. The method according to claim 1, in which at the stage of installation of the forming elements of the transverse power frames:
- install a vacuum bag in the cavity between the pair of the said forming elements of each of the transverse power frames. 4. The method according to claim 1, in which at the stage of laying said fillers for forming a skin of said roof:
- spread the honeycomb core next to the said protrusions to create holes for the loading hatches. 5. The method according to claim 1, in which, after laying out the said layers forming the elements of the lower power binding belt, a shaped U-shaped cross-section silicone insert is installed on these layers to obtain a docking zone of the said roof with the hopper car. 6. The method according to claim 1, in which before removing said roof from said mold, upon completion of said polymerization, a coating is applied to the inner surfaces of said roof to protect against abrasive wear. 7. The method according to claim 1, in which the mechanical processing of the said roof is carried out after removing it from the said mold upon completion of said polymerization. 8. The method according to claim 1, in which after removing said roof from said mold upon completion of said polymerization:
- a wear-resistant coating is applied to the surface of said pedestrian zone;
- install pre-made hinged lids on said openings of loading hatches;
- install at least one pre-made device for equalizing the pressure on the corresponding end wall;
- Attach prefabricated pedestrian barriers and stairs;
- apply fireproof and paint coatings to the outer surfaces of said roof.

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