WO2019162061A1

WO2019162061A1 - Method for producing a large component for rail vehicles, which consists of hollow light-metal profiled sections

Info

Publication number: WO2019162061A1
Application number: PCT/EP2019/052495
Authority: WO
Inventors: Robert Nedelik; Andreas Karl RUTHMEIER; Markus Seitzberger
Original assignee: Siemens Ag Österreich
Priority date: 2018-02-21
Filing date: 2019-02-01
Publication date: 2019-08-29
Also published as: CN111819125B; CN111819125A; AT520978A1; EP3727987B1; ES2941724T3; AT520978B1; PL3727987T3; EP3727987A1; HUE061912T2

Abstract

The invention relates to a method for producing a large component (1) for rail vehicles, said component consisting of hollow light-metal profiled sections (2), wherein said hollow light-metal profiled sections (2) are interconnected in a specific sequence by means of a welding method, and at least some sections of a top layer (3) of the hollow light-metal profiled sections (2) are removed.

Description

description

Process for producing a

Rail vehicle component made of light metal hollow sections.

Technical area

The invention relates to a method for producing a rail vehicle large component of light metal hollow sections and a light metal hollow section.

State of the art

The car body of a passenger rail vehicle can be manufactured by means of so-called integral construction, in which metal profiles are connected to large components and these in turn to a car body. The large components typically provide a side wall, a base, a roof or an end wall, wherein as a joining technique of the metal profiles with each other and to connect the

Large components usually a welding process is used. This design allows a high degree of automation of the production and the use of light metal profiles also a relatively small car body mass. The metal profiles themselves are usually designed as closed hollow profiles and can have additional features, such as fastening strips or weld pool fuses for further manufacturing. These welds have due to certain metallurgical relationships, a lower strength than that

connecting light metal profiles, which makes it expedient to arrange these welds as possible in lightly loaded zones. On locally increased strength requirement of Car bodies, for example, next door or window openings can be received only to a small extent, as the

Metal profiles along their longitudinal extent always have the same cross-section. As such, an integral-body carbody often has a larger mass than would be required to meet strength requirements.

A possible solution to this problem may be by means of

Production of a car body made of light metal in

Differential construction can be found. For steel car bodies, this construction is common, in which the

Large components are constructed from a lattice frame covered with sheet metal of frames and stringers. The outer panel is usually using spot welds or

Fillet welds with the frame structure joined. A steel integral design, which would mean lower manufacturing costs, is not technologically feasible. at

Aluminum car boxes requires a conventional

Differential design a large number of welds, which often can not be produced automatically and thus cause high production costs. Therefore, in addition to the weakening of the material by welding, this construction is avoided in light metal.

Presentation of the invention

The invention is therefore based on the object of specifying a method for producing a rail vehicle large component of light metal hollow sections, which allows to meet specific strength requirements at certain positions of the large component and thereby the lowest possible weight of the large component at high Degree of automation and associated low

To achieve production costs.

The object is achieved by a method having the features of claim 1 and a light metal hollow profile according to claim 7. Advantageous embodiments are the subject

subordinate claims.

The basic idea of the invention is based on a method for producing a rail vehicle component

Light metal hollow sections described, comprising the following steps:

Arranging the light metal hollow profiles in a specific sequence,

- Add the light metal hollow sections with each

adjacent light metal hollow sections by means of a

welding process

- At least partial removal of a cover layer of the

Light metal hollow profiles.

As a result, the advantage can be achieved, a

Rail vehicle large component to be able to build, which is on the one hand automated and inexpensive to produce, on the other hand, as flexible localization of local strength requirements as by means of a

Differential construction.

According to the invention, typically several, light metal hollow sections are connected together and then removed parts of a cover layer of the composite light metal hollow sections. Thus, at positions where there are no increased strength requirements (for example, at a sufficient distance from window cutouts), weight may be present can be saved without significantly reducing the required strength of the large component.

The surface to be removed of the cover layer is of the

Strength requirements for the large component or the car body determined. In order to be able to achieve a relevant weight saving, a large part of the cover layer must be removed, wherein it is advantageous to at least 50% of the area of the inner cover layer of a large component

remove .

It is particularly advantageous to add the light metal hollow profiles to each other by means of an automatable welding process and then to partially remove the cover layer of the composite light metal hollow sections by means of a likewise automatable milling process. This is particularly advantageous, since in a conventional manufacture of a railroad integral component in integral construction, machining (e.g., for the manufacture of window and door cutouts) is to be carried out anyway. The removal of the cover layer can be simply provided as a further step and there are no further transport or setup required.

It is particularly advantageous, the top layer of

At least partially remove composite light metal hollow sections on that side, which in the installed state of the large component, the inside of the

Rail vehicle forms.

The remaining after removal of the cover layer webs form on the one hand stiffening ribs in the large component, On the other hand, they can be used for the attachment of interior fittings such as wall coverings, etc.

In a further development of the invention, these webs below the removed areas of the cover layer also

completely removed when their stiffening

Properties at the relevant location are not required.

A particularly advantageous embodiment of the invention provides to leave below the removed areas of the cover layer also portions of the underlying webs, i. not completely remove these webs.

In this way, the advantage can be achieved of achieving a reduction in the component mass without significantly reducing the dimensional stability. Even short remaining portions of the webs cause a large stiffening of the outer wall, in particular a significantly increased Beulsteifigkeit.

A particularly advantageous embodiment of the invention provides to use light metal hollow sections, which are optimized for the partial removal of the webs out, with the remaining sections of the webs particularly

are designed to increase stiffness.

In this case, the hollow profile can be executed closed with two cover layers, wherein the cover layers are interconnected with webs and wherein the webs have a first portion which is perpendicular to a cover layer and after this first portion, the webs have a branch. If such a hollow profile is processed, wherein the webs are removed so that the first, oriented perpendicular to the cover layer portion and a certain portion of the branch remains, the entire shows

remaining portion of a substantially T-shaped Cross-section. Such a T-shaped cross section of a remaining portion of a web is extremely advantageous because it has a particularly high stiffening of the remaining

Covering ensured and also particularly well for the attachment of other components (such

Interior paneling) is suitable.

Brief description of the drawings

They show by way of example:

Fig.l light metal hollow section.

Fig.2 Connected light metal hollow sections.

Fig.3 rail vehicle large component.

Fig.4 Machined light metal hollow profile.

Fig.5 light metal hollow profile, T-shaped web.

Fig.6 light metal hollow profile, I-shaped web.

Fig.7 light metal hollow profile, double bar.

Fig.8 light metal hollow profile, C-groove.

Fig.9 light metal hollow profile, closed chamber

Fig.10 light metal hollow profile, L-shaped web.

Fig.ll light metal hollow profile, angled web.

Fig.12 light metal hollow profile, T-shaped web,

Gratreduziert.

Fig.13 light metal hollow profile, T-shaped web,

Gratreduziert, central ridges.

Embodiment of the invention Fig.l shows an example and schematically a light metal hollow section. It is a cross section of a light metal hollow section 2 shown, as shown in this subject

Manufacturing process can be used. The light metal hollow section 2 is designed to be closed and has an inner cover layer 3 and an outer cover layer 4. It is finished on the installation arrangement of the profile in one

taken together rail vehicle reference.

On the edge, the light metal hollow profile comprises 2

Connecting devices for positive or non-positive connection with other profiles. Between the cover layers 3, 4 webs 5 are arranged, wherein in gezeem

Embodiment three webs 5 are provided. The webs 5 have an outgoing from the outer cover layer 4 first section 6, which is oriented perpendicular to the outer cover layer 4. In a further sequence, the webs after the first section 6 a branch, which comprises a parallel to the outer cover layer 4 extending portion. The further course of the webs 5, as in conventional profiles in use, obliquely aligned with the cover layers 3, 4.

Figure 2 shows by way of example and schematically connected

Light-metal hollow profiles. There are two juxtaposed light metal hollow sections 2 shown, wherein the

Connecting means for positive or non-positive connection with each other are engaged. In this way, a large-scale rolling stock component can typically be assembled over the entire length of the carriage, with no door or window cutouts still present.

3 shows an example and schematically a

Rail vehicle large component. It is a section of one Rail vehicle major component 1 shown, which is designed as a side wall. The rail vehicle

Large component 1 is made of several light metal hollow sections 2, as shown in Fig. 1,

built up. After joining the individual light metal hollow sections 2 window cutouts 7 and a partial removal of the inner cover layer 4 and the webs 5 have been made. In the illustrated embodiment, the

remaining portions 9 of the inner cover layer 4 as diagonal braces executed, which causes a particularly high shear stiffness of the rail vehicle large component 1. Such a stiffening is required to compensate for the weakening by the window cutouts 7. In the partially removed regions 8, portions of the webs 5 have been preserved and form a bulge-resistant support structure arranged close to the outer cover layer 4.

Fig. 4 shows by way of example and schematically a machined light metal hollow profile. It is the light metal hollow profile 2 from Fig.l after removal of part of the inner

Cover layer 3 and the webs 5 shown. The remaining part of the webs 5 in this case has a substantially T-shaped cross-section and thereby offers a high increase in the Beulsteifigkeit the profile.

Figures 5 to 12 illustrate embodiments of light metal hollow sections, which can be used in representational process. In each case, a section through a machined profile is shown, wherein in each case a cross section of a web is shown. In this case, the sections of the web to be removed and the removed inner cover layer are drawn by dashed lines. Fig. 5 shows by way of example and schematically a light metal hollow profile with a T-shaped web. The light metal hollow profile 2 is shown in that embodiment, which is shown in Figs. 1 to 4 applied. The profile 2 has an inner cover layer 3, which faces the interior of a constructed from the profile 2 rail vehicle in the installed state, further comprises an outer cover layer 4. The cover layers 3, 4 are connected to webs 5, wherein a first portion 6 of the outer cover layer 4 extends vertically and spaced from the outer cover layer 4 in an inner belt 10 branches. This inner belt 10 causes a large increase in the Beulsteifigkeit the

remaining outer cover layer 4 after removal of the webs 5 and the inner cover layer 3. Starting from the edge lines of the inner belt 10, webs 5 extend at an angle to the inner cover layer 3.

Fig. 6 shows by way of example and schematically a light metal hollow profile with an I-shaped web. It is a

Light metal hollow section 2, similar to that shown in Figure 5, but with no inner belt is provided, but on the outer cover layer 4 facing away from the end of the first portion 6, the webs branch 5 angled. This embodiment can be used when the high

Beulsteifigkeit the profile of Fig. 1 is not required.

Fig. 7 shows by way of example and schematically a light metal hollow profile with a double web. According to this embodiment, the light metal hollow section 2 has an outer

Cover layer 4 directly attached hollow chamber formed of two vertical webs and a belt, wherein of the Corners of this closed chamber in each case a web 5 to the inner cover layer 3 is angled. In processed

Condition of this light metal hollow section 2 remain two vertical sections 6 in the form of a double web.

8 shows an example and schematically a light metal hollow profile with a C-groove. Fig. 8 illustrates the light metal hollow section 2 of Fig. 7, but with the machining done so that only the angled ridges 5 and a central part of the inner belt 10 are removed. Thus, two L-shaped, mutually facing webs, which form a C-groove and can be used for the attachment of other components remain. 9 shows by way of example and schematically a light metal

Hollow profile with a closed chamber. Fig. 9 illustrates the light metal hollow section 2 of Fig. 7, but with the machining done so that only the angled webs 5 are removed and the inner belt 10 remains. Thus, a closed chamber on the outer cover layer 4 is arranged on the machined hollow section 2.

Fig.10 shows an example and schematically a light metal hollow profile with an L-shaped web. The light metal

Hollow section 2 has an inner belt 10 following the first section 6, at whose ends in each case a web 5 extends at an angle. The inner belt 10 extends only to one side of the first portion 6 and thus forms together with this first portion 6 an L-shaped web.

Fig.ll shows an example and schematically a light metal hollow profile with an angled web. This embodiment a light metal hollow profile 2 substantially corresponds to that which is shown in Fig. 6, wherein the first portion 6 is angled to the outer cover layer 4 is arranged.

Fig. 12 shows by way of example and schematically a light metal hollow profile with a T-shaped web. It is a

Light metal hollow section 2 shown, which is constructed very similar to the profile of FIG. The profile of FIG. 5 has a disadvantage, since after the machining to remove the webs 5 burrs remain on the inner belt 10, since the cutting edge for removing the webs 5, the inner belt 10 slicing intersects. In such a place, the burr formation is inevitable and it will be

Reworking is required to remove these burrs. FIG.

FIG. 11 shows a light metal hollow profile 2, which ensures a significantly reduced-lored cut in the removal of the webs 5. For this purpose, the inner belt 10 is executed at its ends in each case with a thickening and the webs 5 start from the inner cover layer 3 facing side of these thickenings. At a distance of the webs 5 by means of a machining process, the burr formation is thus significantly reduced at this point.

Fig. 13 shows by way of example and schematically a light metal hollow profile with a T-shaped web. It is a

Light metal hollow profile 2 shown in the

Substantially corresponds to that of FIG. 5, but the webs 5 go out centrally from the inner belt 10. By laying the approach of the webs 5 from the edges to the middle accounts for the burr-vulnerable cuts in the removal of the webs. 5 List of terms

Railcar United component

Light-metal hollow profiles

Inner cover layer

Outer cover layer

web

first section

pane

Removed sections of the inner cover layer Remaining sections of the inner cover layer Inner strap

Claims

claims

1. A method for producing a

Rail vehicle component (1) made of light metal hollow sections (2),

with the following process steps:

Arranging the light metal hollow profiles (2) in a specific sequence,

- joining the light metal hollow sections (2) with the respective adjacent light metal hollow sections (2) by means of a welding process,

characterized in that

- An at least partial removal of a cover layer (3) of the light metal hollow sections (2) takes place, wherein in addition to the cover layer (3) and webs (5) within the

Light metal hollow sections (2) are removed.

2. Method for producing a

Rail vehicle component (1) made of light metal hollow sections (2) according to claim 1,

characterized in that the at least partially removed cover layer (3) as the inside of a

Railway vehicle is formed.

3. Process for producing a

Rail vehicle component (1) made of light metal hollow sections (2) according to one of claims 1 or 2, characterized in that for removing the

Cover layer (3) and the webs (5) a milling method is used.

4. Process for producing a

Rail vehicle component (1) made of light metal hollow sections (2) according to one of claims 1 to 3, characterized in that below the removed areas of the cover layer (3) sections of webs (5) remain.

5. Method for producing a

Rail vehicle component (1) made of light metal hollow sections (2) according to claim 4,

characterized in that the remaining

Sections of the webs (5) have a substantially T-shaped cross-section.

6. Process for producing a

Rail vehicle component (1) made of light metal hollow sections (2) according to one of claims 1 to 5, characterized in that more than 50% of the surface of a cover layer (3) of the light metal hollow sections (2) are removed.

7. Light metal hollow section (2) for use in a method for producing a

Rail vehicle component (1) according to one of claims 1 to 6,

characterized in that the hollow profile (2) closed with two cover layers (3, 4) is executed, wherein the cover layers (3, 4) with webs (5) are interconnected and wherein the webs (5) starting from a cover layer (4 ) have a first portion (6) and after this first portion (6), the webs (5) have a branch.