Truck frame for railway vehicle and method for manufacturing truck frame for railway vehicle

Abstract

To improve the manufacturing efficiency of a truck frame for a railway vehicle by reducing positioning of members and a workload relating to welding in the case of welding a plurality of long members to manufacture the truck frame for a railway vehicle.SOLUTION: A method for manufacturing a truck frame for a railway vehicle includes: preparing a plurality of members including at least one first long member having a plate part and a projection part continuous to the plate part to project outward from one plate surface of the plate part when viewed from a longitudinal direction, and at least one long second member extending in the longitudinal direction of the first members; and forming a hollow beam having a closed space surrounded by the plurality of members when viewed from the longitudinal direction by welding the first member and the second member to a side surface of the projection part of the first member in a state in which a plate surface of the second member is in contact from both sides of the first member in a width direction.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a bogie frame for a rail vehicle and a method for manufacturing a bogie frame for a rail vehicle. [Background technology]

[0002] Patent Document 1 describes a method for manufacturing a bogie frame for a railway vehicle, in which first and second side beam members formed by processing a long flat plate are joined by means of welding or the like to form a side beam main body having a rectangular closed cross section. In this method, before joining the first and second side beam members, a plurality of reinforcing members are welded to the inside of each side beam member, and a backing metal is welded to the welded portion of the butt joint of each side beam member. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 4428767 Summary of the Invention [Problem to be solved by the invention]

[0004] When welding together long members that are relatively heavy and long, such as the side beam members described in Patent Document 1, the members must be aligned with high precision before welding. In addition, when welding multiple reinforcing members to a member, the amount of welding increases and welding must be performed in a narrow space within the member. This increases the workload and reduces the manufacturing efficiency of the bogie chassis for railway vehicles.

[0005] Therefore, the present disclosure aims to improve the manufacturing efficiency of railway vehicle bogie frames by reducing the workload associated with aligning components and welding when manufacturing railway vehicle bogie frames by welding multiple long components. [Means for solving the problem]

[0006] A manufacturing method for a bogie frame for a railway vehicle according to one embodiment of the present disclosure includes preparing a plurality of members including at least one elongated first member having, when viewed in the longitudinal direction, a plate portion and a convex portion that is continuous with the plate portion and protrudes outward from one plate surface of the plate portion, and at least one elongated second member extending in the longitudinal direction of the first member; and welding the first member and the second member together in a state in which the plate surfaces of the second member are in contact with side surfaces of the convex portion of the first member from both sides in the width direction of the first member, thereby forming a hollow beam having a closed space surrounded by the plurality of members when viewed in the longitudinal direction. Effect of the Invention

[0007] According to one aspect of the present disclosure, when manufacturing a railway vehicle bogie frame by welding a plurality of long components, the manufacturing efficiency of the railway vehicle bogie frame can be improved by reducing the workload associated with aligning the components and welding. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a partial side view of a railway vehicle according to a first embodiment. [Diagram 2] FIG. 2 is a schematic diagram of the automatic welding system according to the first embodiment. [Diagram 3] FIG. 3 is a cross-sectional view of a workpiece viewed from the longitudinal direction immediately before welding according to the first embodiment. [Figure 4] FIG. 4 is a partial cross-sectional view showing a state in which the first plate material and the second plate material of FIG. 3 are welded together. [Diagram 5] FIG. 5 is a cross-sectional view of a first member according to a first modified example of the first embodiment, as viewed in the longitudinal direction. [Figure 6] FIG. 6 is a cross-sectional view of a first member according to a second modified example of the first embodiment, as viewed from the longitudinal direction. [Figure 7] FIG. 7 is a cross-sectional view of a first member according to a third modified example of the first embodiment, as viewed from the longitudinal direction. [Figure 8]FIG. 8 is a cross-sectional view of the first member and the second member according to the fourth modified example of the first embodiment, as viewed from the longitudinal direction. [Figure 9] FIG. 9 is a side view of a first member according to a fifth modified example of the first embodiment. [Figure 10] FIG. 10 is a side view of a first member according to a sixth modified example of the first embodiment. [Figure 11] FIG. 11 is a cross-sectional view of a workpiece viewed from the longitudinal direction immediately before welding according to the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Each embodiment will be described below with reference to the drawings. Unless otherwise specified, the "longitudinal direction" referred to below refers to the longitudinal direction of the first member, which is a component of the hollow beam of the bogie frame. Conventionally, when preparing a plurality of formed members formed by bending processing by a process such as a press process, and assembling a structure by butt welding the plurality of formed members together, the shape of the formed members after bending processing may be restored by springback, and the butt positions of the formed members may not match, resulting in a step. The "misalignment" referred to below refers to such a step.

[0010] (First embodiment) FIG. 1 is a partial side view of a railcar 60 according to a first embodiment. The railcar 60 includes a bogie 50 and a car body 51. The railcar 60 is, for example, a passenger car, but may be a freight car. The bogie 50 includes a bogie frame 52 extending in the longitudinal direction of the car body 51, and a plurality of wheels 53 supporting the bogie frame 52 on the track. The bogie frame 52 includes at least one hollow beam P. As an example, the bogie frame 52 includes a pair of side beams 54 and a cross beam 55 connecting the pair of side beams 54 in the vehicle width direction at the center of the longitudinal direction. The at least one hollow beam P is, for example, at least one of the side beam 54 and the cross beam 55. The type of the beam P is not limited, and may be, for example, a joint beam provided on the bogie frame 52 and connecting a pair of adjacent cross beams 55. As an example, the beam P is an elongated member having a length dimension larger than the diameter of the wheels 53.

[0011] Conventionally, when manufacturing a bogie frame, for example, after forming a plurality of beams, the plurality of beams are welded together. When forming a plurality of beams, for example, a task of aligning and welding long members, which are components of the beams, with high accuracy is required. Also, for example, when welding a plurality of reinforcing members to a long member, a task of welding each reinforcing member to a plurality of locations in a narrow space within the member is required. In contrast, in this embodiment, as shown below, the bogie frame 52 is manufactured by forming a beam P using a workpiece W, which is a plurality of members of a predetermined shape that are prepared in advance. This prevents a decrease in the manufacturing efficiency of the bogie frame 52 due to the workload of aligning and welding a plurality of members.

[0012] In this embodiment, as an example, a bogie frame 52 is manufactured using an automatic welding system 1 (hereinafter also simply referred to as system 1). Fig. 2 is a schematic diagram of the system 1 according to the first embodiment. As shown in Fig. 2, the system 1 includes, for example, an equipment group 2, at least one articulated robot 3, a control device 4, a tool changer 5, and a positioner 6. The system 1 performs multiple processes, including welding, on the workpiece W by properly using multiple devices in the equipment group 2, without having to move the workpiece W significantly to another location.

[0013] The equipment group 2 includes a welding device 10. As an example, the welding device 10 is a TIG (Tangsten Inert Gas) welding device. The welding method of the welding device 10 is not limited to the TIG welding method, and may be other welding methods such as Hot TIG welding, submerged arc welding, electroslag welding, and gas-shielded arc welding. As the gas-shielded arc welding method, for example, MAG (Metal Active Gas) welding or MIG (Metal Inert Gas) welding can be mentioned. When not in use, the equipment group 2 is arranged on a rack 7. As an example, the rack 7 has a plurality of holders 7a that individually and detachably hold each of the devices in the equipment group 2.

[0014] A specific device (hereinafter also simply referred to as a specific device) selected from the device group 2 is detachably attached to the articulated robot 3. The tool changer 5 detachably attaches the specific device to the articulated robot 3. For the tool changer 5, see, for example, JP 2020-93348 A.

[0015] The control device 4 controls the specific device and the articulated robot 3. The control device 4 of this embodiment has a control processing circuit that individually controls each of the specific device, the articulated robot 3, and the tool changer 5. As an example, the control device 4 has a memory 15 in which a program is stored, and a processor 16 that executes the program stored in the memory 15. The control processing circuit is realized by the memory 15 and the processor 16. The processor 16 that has read the program is configured to execute control of the articulated robot 3 so as to attach and detach the specific device to and from the articulated robot 3.

[0016] The positioner 6 positions the workpiece W relative to the articulated robot 3. The positioner 6 has a base 17 and a table 18. The workpiece W is placed on the table 18. The table 18 is supported by the base 17 so that the inclination angle of the upper surface with respect to the horizontal plane is adjustable. A holder for detachably holding the workpiece W may be separately disposed on the table 18. The positioner 6 is controlled by the control device 4. The workpiece W is, for example, an intermediate product of a beam P.

[0017] The manufacturing method of the bogie frame 52 of this embodiment includes a preparation step S1 of preparing a predetermined plurality of members (hereinafter, also simply referred to as a plurality of members) constituting the workpiece W, and a formation step S2 of forming a beam P from the plurality of members. The preparation step S1 includes preparing a workpiece W including at least one long first member 20 and at least one long second member 21 (see FIG. 3) as the plurality of members. The formation step S2 includes forming a hollow beam P having a closed space Q surrounded by the plurality of members as viewed in the longitudinal direction by welding the first member 20 and the second member 21. At least a part of the preparation step S1 and the formation step S2 may be executed by the processor 16, and the remaining part may be executed by an operator. In this embodiment, as an example, the preparation step S1 is executed by an operator, and the formation step S2 is executed by the processor 16.

[0018] FIG. 3 is a cross-sectional view of the workpiece W just before welding according to the first embodiment, as viewed from the longitudinal direction. FIG. 3 shows a schematic diagram of a plurality of members positioned relative to each other by the system 1 and a predetermined jig. As shown in FIG. 3, the first member 20 has a plate portion 20a and a protruding portion 20c that is continuous with the plate portion 20a and protrudes outward from one plate surface 20b of the plate portion 20a, as viewed from the longitudinal direction. The side surfaces of the plate surface 20b and the protruding portion 20c extend in the longitudinal direction of the first member 20. The second member 21 extends in the longitudinal direction of the first member 20. The plate surface 21a of the second member 21 extends in the longitudinal direction of the second member 21. As an example, the maximum dimension of the thickness of the first member 20 is equal to or greater than the maximum dimension of the thickness of the second member 21. As an example, the maximum dimension of the thickness is the thickness dimension of the region in which the protruding portion 20c of the first member 20 is arranged.

[0019] As an example, at least one first member 20 includes a pair of first plate materials 25, 26, and at least one second member 21 includes a pair of second plate materials 27, 28. The first plate materials 25, 26 have plate portions 25a, 26a which are plate portion 20a, plate surfaces 25b, 26b which are plate surface 20b, and convex portions 25c, 26c which are convex portion 20c. The pair of second plate materials 27, 28 have plate surfaces 27a, 28a which are plate surface 21a.

[0020] As another example, the pair of second plate materials 27, 28 have inclined portions 27b, 28b arranged on both sides in the width direction, where plate surfaces 27a, 28a are inclined so that the thickness dimension decreases from the center in the width direction toward the outside. The surfaces of the inclined portions 27b, 28b are exposed to the outside. As a result, when the plate materials 25 to 28 are combined, grooves R are formed between the first plate material 25 and the second plate materials 27, 28, and between the first plate material 26 and the second plate materials 27, 28.

[0021] When manufacturing the bogie frame 52, in a preparation step S1, a worker prepares at least one long first member 20 and at least one long second member 21 as a plurality of members. At this time, as one example, the worker combines the plurality of members so that the plate surface 21a of the second member 21 contacts the side surface of the protruding portion 20c of the first member 20 from both sides in the width direction of the first member 20. In this state, in a formation step S2, the processor 16 welds the first member 20 and the second member 21 to form a hollow beam P having a closed space Q surrounded by the plurality of members as viewed in the longitudinal direction.

[0022] Specifically, in the preparation step S1 of this embodiment, the worker prepares the plate materials 25 to 28. The worker also arranges the pair of first plate materials 25, 26 with their plate surfaces 25b, 26b facing each other. The worker also arranges the pair of second plate materials 27, 28 with their plate surfaces 27a, 28a facing each other. At this time, the worker brings the plate surfaces 27a, 28a of the pair of second plate materials 27, 28 into contact with the side surfaces 25d, 26d of the respective convex portions 25c, 26c of the pair of first plate materials 25, 26. As a result, the worker combines and arranges the plate materials 25 to 28 so that a closed space Q surrounded by the plate materials 25 to 28 is formed. When arranging the plate materials 25 to 28, a jig is used as necessary. Thereafter, the processor 16 arranges the plate materials 25 to 28 combined by the worker on the table 18, and welds the plate materials 25 to 28 to form a beam P. In the example shown in FIG. 3, the closed space Q has a rectangular shape when viewed in the longitudinal direction.

[0023] The preparation step S1 may also include preparing a first member 20 having a plate portion 20a and a protruding portion 20c both formed by machining. The plate portion 20a and the protruding portion 20c of the first member 20 are formed with higher precision by machining compared to a case where the machining is not performed. In addition, the flatness of the plate surfaces 25b, 26b and the side surfaces 25d, 26d, which are the multiple surfaces of the plate portion 20a and the protruding portion 20c of the first member 20, is improved. Therefore, when the first member 20 and the second member 21 are combined, for example, the generation of unnecessary gaps between the first member 20 and the second member 21 is suppressed.

[0024] The preparation step S1 may include preparing the second member 21 having the plate surface 21a formed by machining. In another example, the preparation step S1 may include preparing the first member 20 and the second member 21 each formed by at least one of machining methods including machining, rolling, casting, and forging.

[0025] FIG. 4 is a partial cross-sectional view showing the state of the first plate material 26 and the second plate material 27 in FIG. 3 during welding. As shown in FIG. 4, the second plate material 27 is held in a state in which the plate surface 27a of the width direction end is in surface contact with the side surface 26d of the protruding portion 26c of the first plate material 26, and the width direction end is positioned at a distance from the plate surface 26b of the first plate material 26. In this state, the processor 16 controls at least one of the welding device 10, the articulated robot 3, and the positioner 6 so as to form a weld bead B inside the groove R from the outside in the width direction of the first plate material 26. As a result, a sufficient amount of weld bead B is formed inside the groove R, and full penetration welding is performed. Note that the processor 16 also executes similar processing in welding between the first plate material 26 and the second plate material 28, and welding between the first plate material 25 and the second plate materials 27 and 28. As a result, the workpiece W has a plurality of welded portions where the plate materials 25 to 28 are welded together.

[0026] Thus, the preparation step S1 of this embodiment includes preparing the second member 21 having a shape in which a groove R exposed to the outside is formed between the first member 20 and the second member 21. The groove R is formed by arranging the first plate materials 25, 26, which are the first members, and the second plate materials 27, 28, which are the second member 21, so that the inclined portions 27b, 28b are exposed to the outside.

[0027] In addition, when welding the first member 20 and the second member 21, the processor 16 welds the first member 20 and the second member 21 by a full penetration welding method, for example. As a result, the second member 21 is welded to the first member 20 in the entire region of the thickness part of the second member 21. The full penetration welding here refers to welding the second member 21 by penetrating into the first member 20 over the entire region in the thickness direction. In this embodiment, this full penetration welding is realized by the first member 20 functioning as a backing metal by contacting the side surface 25d of the first member 20 with the plate surface 21a of the second member 21. As shown in FIG. 3, in this embodiment, since the first member 20 has a convex portion 20c, it is not necessary to separately arrange a backing metal, which is a solid material, so as to contact the plate surface 21c of the pair of plate surfaces 21a of the second member 21 opposite to the plate surface 21b exposed to the outside. Therefore, the first member 20 and the second member 21 are fully penetrated welded together without the need to prepare a separate backing metal and align the backing metal with respect to the first member 20 and the second member 21. For the sake of explanation, in Fig. 4, the boundaries between the members 20, 21 and the weld bead B are clearly shown in a schematic manner.

[0028] For example, the processor 16 continuously welds the first member 20 and the second member 21 in their respective longitudinal directions. The processor 16 also controls at least one of the positioner 6 and the articulated robot 3 to adjust the relative position of the welding device 10 with respect to the workpiece W, thereby sequentially welding the respective planned welding locations of the first member 20 and the second member 21. During this welding, the processor 16 welds the first member 20 and the second member 21 from the outside in the width direction of the first member 20, so that there is no need to weld the first member 20 and the second member 21 from between a pair of second members 21, for example. After the formation process S2 is completed, the processor 16 or an operator welds the formed hollow beam P to other parts to manufacture the bogie frame 52.

[0029] As described above, the manufacturing method of the bogie frame 52 of this embodiment includes preparing a plurality of members including at least one elongated first member 20 and at least one elongated second member 21, and forming a hollow beam P having a closed space Q by welding the first member 20 and the second member 21 together while contacting the plate surface 21a of the second member 21 with the side surface of the convex portion 20c of the first member 20 from both sides in the width direction of the first member 20.

[0030] According to this manufacturing method, by contacting the plate surface 21a of the second member 21 with the side surface of the convex portion 20c of the first member 20, the first member 20 and the second member 21 can be quickly aligned while preventing the occurrence of misalignment that occurs, for example, when the first member 20 and the second member 21 are butted together. This reduces the alignment work. In addition, since the plate portion 20a and the convex portion 20c of the first member 20 are continuous, for example, the work of welding a separate convex portion to the plate portion 20a and attaching it can be avoided. In addition, since the first member 20 and the second member 21 can be welded from the outside in the width direction of the first member 20 with the plate surface 21a of the second member 21 in contact with the side surface of the convex portion 20c of the first member 20, the number of welded points can be reduced compared to the case of welding from both sides of the second member 21, and the welding work can be performed using a wide space outside the first member 20 and the second member 21. This reduces the workload involved in aligning and welding the members. As a result, the manufacturing efficiency of the bogie frame 52 can be improved.

[0031] Furthermore, according to the manufacturing method, the first member 20 and the second member 21 can be aligned with high accuracy, so that the relative positions of the articulated robot 3 and the welding device 10, and the workpiece W, can be prevented from varying for each workpiece W. Therefore, by using the system 1, the beam P can be formed with stable quality, and the bogie frame 52 can be efficiently manufactured.

[0032] Furthermore, according to the manufacturing method, when the beam P is formed, a welded portion is formed mainly on the outer side in the width direction of the first member 20. Because this welded portion is exposed to the outside, it is possible to easily check the welded portion from outside even after the manufacture of the bogie frame 52. This makes it easier to inspect the state of the welded portion from outside the bogie frame 52 after the manufacture, and improves the inspection accuracy. This makes it easier to maintain high welding quality.

[0033] In the manufacturing method of this embodiment, at least one first member 20 includes a pair of first plate materials 25, 26, and at least one second member 21 includes a pair of second plate materials 27, 28. Forming the beam P includes arranging the pair of first plate materials 25, 26 with their plate surfaces 25b, 26b facing each other, arranging the pair of second plate materials 27, 28 with their plate surfaces 27a, 28a facing each other, and contacting the plate surfaces 27a, 28a of the pair of second plate materials 27, 28 with the side surfaces 25d, 26d of the protruding parts 25c, 26c of the pair of first plate materials 25, 26 to form a closed space Q, thereby welding the pair of first plate materials 25, 26 and the pair of second plate materials 27, 28 to form a beam P.

[0034] According to this manufacturing method, the beam P can be formed using a plurality of members, which are a total of four plate materials. Therefore, for example, it is not necessary to prepare a plurality of long formed members formed by bending and butt-weld the plurality of formed members to form the hollow beam P. This makes it possible to avoid partial variation in the shape of the members during bending, and to form the beam P with even higher precision. Therefore, a high-quality bogie frame 52 can be efficiently manufactured. In addition, since the thickness dimensions of the first member 20 and the second member 21 can be set individually, for example, even when a small amount of reinforcing material is used or when no reinforcing material is used, it is easy to manufacture the bogie frame 52 having appropriate strength.

[0035] The system 1 may include a plurality of articulated robots 3. When the system 1 includes a plurality of articulated robots 3, for example, it is possible to simultaneously weld welded joints at a plurality of locations. This makes it possible to significantly reduce the manufacturing time of the bogie frame 52. Note that a system in which two articulated robots 3 are arranged is also called a tandem robot system.

[0036] Next, a modified example of this embodiment will be described, focusing on the differences from this embodiment. FIG. 5 is a cross-sectional view of the first member 120 according to the first modified example of the first embodiment, viewed from the longitudinal direction. FIG. 6 also illustrates the second plate materials 27, 28, which are the second member 21, and the weld bead B. As shown in FIG. 5, the protruding portion 120c of the first member 120 has an extending portion 120e extending in the width direction of the first member 120, and at least one recessed portion 120f recessed in the thickness direction of the plate portion 120a midway through the extending portion 120e, when viewed from the longitudinal direction. The recess depth and width dimension of the recessed portion 120f can be appropriately set, for example, within the range of the balance between strength and weight required for the first member 120.

[0037] Fig. 6 is a cross-sectional view of a first member 220 according to a second modified example of the first embodiment, viewed from the longitudinal direction. Fig. 6 also illustrates a second plate material 27, which is the second member 21, and a weld bead B. As shown in Fig. 6, when viewed from the longitudinal direction, the first member 220 has an inclined portion 220e that slopes downward from the middle of the side surface of the protruding portion 220c toward the plate surface 220f of the first member 220. As a result, the first member 220 is formed so that the base portion of the protruding portion 220c is flared toward the end.

[0038] When the bogie frame 52 is manufactured, the tip end of the second member 21 in the width direction is disposed at the apex of the inclined portion 220e, which is the intersection point between the convex portion 220c and the inclined portion 220e, as viewed in the longitudinal direction. The position of the tip end of the second member 21 in the width direction coincides with the position of the apex of the inclined portion 220e, and the plate surface 21a of the second member 21 comes into contact with the side surface of the convex portion 220c, so that the second member 21 and the first member 220 are positioned relatively to each other. The position of the apex of the inclined portion 220e in the thickness direction of the plate portion 220b of the first member 220 and the position of the intersection point between the plate surface 220f of the first member 220 and the inclined portion 220e can be appropriately set within a range of balance between strength and weight required for the first member 220, for example.

[0039] 7 is a cross-sectional view of a first member 320 according to a third modified example of the first embodiment, seen from the longitudinal direction. In FIG. 7, the second plate material 27, which is the second member 21, and the weld bead B are also shown. As shown in FIG. 7, the first member 320 has a convex portion 320c, similar to the convex portion 20c of the first member 20 in the first embodiment, but the plate surface 21a of the second member 21 contacts the side surface 320d of the convex portion 320c, and the width direction tip of the second member 21 contacts the plate surface 320b of the first member 320. As a result, the second member 21 and the first member 320 are positioned relative to each other, and the dimensional accuracy of the product can be improved.

[0040] FIG. 8 is a cross-sectional view of the first member 420 and the second member 421 according to the fourth modified example of the first embodiment, as viewed from the longitudinal direction. In FIG. 8, the weld bead B is also illustrated. As shown in FIG. 8, the first member 420 includes a pair of first plate members 425, 426 having different width dimensions of the protruding portions 425c, 426c. As a result, the interval between the pair of second plate members 427, 428 expands from one of the pair of first plate members 425, 426 to the other. In the example shown in FIG. 8, as viewed from the longitudinal direction, the side surface 425d of the protruding portion 425c is inclined with respect to the plate surface 425b of the plate portion 425a of the first plate member 425, and the side surface 426d of the protruding portion 426c is inclined with respect to the plate surface 426b of the plate portion 426a of the first plate member 426. The side surfaces 425d, 426d are in surface contact with the plate surfaces 427a, 428a of the second plate members 427, 428. As a result, the closed space Q has a trapezoidal shape when viewed from the longitudinal direction. In this way, the shape of the closed space Q when viewed from the longitudinal direction is not limited to only a rectangular shape.

[0041] FIG. 9 is a side view of a first member 520 according to a fifth modified example of the first embodiment. In FIG. 9, the upper side of the paper corresponds to the upper side in the vertical direction. As shown in FIG. 9, a convex portion 520c connected to a plate portion 520a of the first member 520 includes a pair of inclined regions 520h, 520i whose upper surface in the protruding direction is inclined downward from both ends in the longitudinal direction toward the inside. The first member 520 also has a through hole 520j disposed between the pair of inclined regions 520h, 520i in the longitudinal direction and penetrating the first member 520 in the thickness direction. In the bogie frame 52, the first member 520 is disposed in a state in which the pair of inclined regions 520h, 520i are exposed to the closed space Q. According to this modified example, for example, liquid that has entered the closed space Q when the beam P is formed, or water such as condensation water that has entered the closed space Q in the bogie frame 52 after manufacture, is guided by the pair of inclined regions 520h, 520i and efficiently discharged to the outside through the through hole 520j.

[0042] FIG. 10 is a side view of a first member 620 according to a sixth modified example of the first embodiment. As shown in FIG. 10, the first member 620 has a plurality of recessed portions 620k recessed from the upper surface in the protruding direction of the convex portion 620c continuous with the plate portion 620a toward the thickness direction of the first member 620. In the example shown in FIG. 10, the plurality of recessed portions 620k are arranged apart from each other in the longitudinal direction of the first member 620. The first member 620 is lighter than the first member 620 without the recessed portions 620k. Each recessed portion 620k has a size and a recessed depth set within a range that can maintain the strength required for the first member 620 and can reduce the weight of the first member 620. Two of the plurality of recessed portions may differ from each other in at least one of the size and the recessed depth. Next, the second embodiment will be described, focusing on the difference from the first embodiment.

[0043] Second embodiment 11 is a cross-sectional view of the workpiece Y seen from the longitudinal direction immediately before welding according to the second embodiment. The workpiece Y has at least one first member 20 and at least one second member 21. In this embodiment, the at least one first member 20 is a single first member 20 having a plate portion 20a and a protruding portion 20c. As an example, the first member 20 is a first plate material 26.

[0044] Moreover, at least one second member 21 is a single second member 221. As an example, the second member 221 has a pair of first plate portions 221b and a second plate portion 221c connecting the pair of first plate portions 221b when viewed in the longitudinal direction. The pair of first plate portions 221b each have a plate surface 221a which is the plate surface 21a of the second member 21. As an example, the pair of first plate portions 221b have an inclined portion 221d for forming a groove R between the pair of first plate portions 221b and the first member 20. The inclined portion 221d has a configuration similar to that of the inclined portions 27b and 28b.

[0045] As shown in FIG. 11, specifically, in the preparation step S1, the worker prepares the first member 20 and the second member 221 so as to place the first member 20 and the second member 221 near the table 18. Thereafter, in the formation step S2, the processor 16 brings each plate surface 221a of the pair of first plate portions 221b of the second member 221 into contact with the side surface 20d of the protruding portion 20c of the first member 20. As a result, the processor 16 forms a closed space Q by the plate portion 20a of the first member 20, the pair of first plate portions 221b of the second member 221, and the second plate portion 221c of the second member 221. In this state, the processor 16 welds the first member 20 and the second member 221. At this time, as an example, the processor 16 forms a weld bead B inside each groove R in the longitudinal direction of the first member 20. In this way, the processor 16 forms a hollow beam P having a closed space Q surrounded by a plurality of members when viewed in the longitudinal direction. In the example shown in Fig. 11, the closed space Q has a rectangular shape when viewed in the longitudinal direction.

[0046] Thus, in the manufacturing method of the second embodiment, forming the beam P includes bringing each plate surface 221a of the pair of first plate portions 221b of the second member 221 into contact with the side surface 26d of the protruding portion 20c of the first member 20, and welding the first member 20 and the second member 221 together in a state in which a closed space Q is formed by the plate portion 20a of the first member 20, the pair of first plate portions 221b of the second member 221, and the second plate portion 221c of the second member 221, to form the beam P. In the second embodiment, the same effect as in the first embodiment is achieved. Furthermore, according to the manufacturing method of the second embodiment, the amount of welding in the forming step S2 is reduced, for example, compared to the manufacturing method of the first embodiment.

[0047] The functions of the elements disclosed herein can be performed using circuits or processing circuits, including general purpose processors, special purpose processors, integrated circuits, ASICs (Application Specific Integrated Circuits), conventional circuits, or combinations thereof, configured or programmed to perform the disclosed functions. Processors are considered processing circuits or circuits because they include transistors and other circuits. In this disclosure, a circuit, unit, or means is hardware that performs the recited functions or hardware that is programmed to perform the recited functions. The hardware may be hardware disclosed herein or other known hardware that is programmed or configured to perform the recited functions. In the case where the hardware is a processor that is considered a type of circuit, the circuit, means, or unit is a combination of hardware and software, and the software is used to configure the hardware, the processor, or the combination of the hardware and the processor.

[0048] As described above, the embodiment and the modified example have been described as examples of the technology disclosed in the present application. However, the technology in the present disclosure is not limited to this, and can be applied to embodiments in which modifications, replacements, additions, omissions, etc. have been made as appropriate. In addition, it is also possible to combine the components described in the embodiment and the modified example to form a new embodiment. For example, a part of the configuration in one embodiment may be applied to another configuration, and a part of the configuration in an embodiment can be separated from other configurations in the embodiment and arbitrarily extracted. In addition, among the components described in the attached drawings and detailed description, not only components essential for solving the problem but also components that are not essential for solving the problem are included in order to exemplify the technology. In each of the above embodiments, a manufacturing method for manufacturing the bogie frame 52 using the system 1 has been exemplified. However, the manufacturing method of the present disclosure may be, for example, a method using equipment other than the system 1. In addition, the manufacturing method of the present disclosure may be a method for manufacturing the bogie frame 52 by a worker.

[0049] (Disclosure items) Each of the following sections is a disclosure of a preferred embodiment. [Item 1] Preparing a plurality of members including at least one elongated first member having a plate portion and a protruding portion that is continuous with the plate portion and protrudes outward from one plate surface of the plate portion when viewed in a longitudinal direction, and at least one elongated second member extending in the longitudinal direction of the first member; and welding the first member and the second member together in a state in which plate surfaces of the second member are in contact with side surfaces of the convex portion of the first member from both sides in a width direction of the first member, thereby forming a hollow beam having a closed space surrounded by the multiple members when viewed from the longitudinal direction.

[0050] According to the method, by bringing the plate surface of the second member into contact with the side surface of the convex portion of the first member, the first member and the second member can be quickly aligned while preventing the occurrence of misalignment that occurs when, for example, the first member and the second member are butted together. This reduces the amount of alignment work. In addition, since the plate portion and the convex portion of the first member are continuous, for example, the work of welding and attaching a separate convex portion to the plate portion can be avoided. In addition, since the first member and the second member can be welded from the outside in the width direction of the first member while the plate surface of the second member is in contact with the side surface of the convex portion of the first member, the number of welding points can be reduced compared to welding from both sides of the second member, and the welding work can be performed using a wide space outside the first member and the second member. This reduces the workload involved in aligning and welding the members together. As a result, the manufacturing efficiency of the bogie frame can be improved.

[0051] [Item 2] the at least one first member includes a pair of first plate members each having the plate portion and the protrusion portion, The at least one second member includes a pair of second plate members, forming the beam Item 2. A manufacturing method for a railway vehicle bogie chassis as described in item 1, comprising: arranging the pair of first plate materials with the plate surfaces facing each other, arranging the pair of second plate materials with the plate surfaces facing each other, and contacting the plate surfaces of each of the pair of second plate materials with the side surfaces of the convex portions of each of the pair of first plate materials to form the closed space, and then welding the pair of first plate materials and the pair of second plate materials to form the beam.

[0052] According to the method, a beam can be formed using a plurality of members, which is a total of four plate materials including a pair of first plate materials and a pair of second plate materials. Therefore, for example, the work of forming a beam by bending a plurality of long members is not required. This makes it possible to avoid partial variation in the shape of the members during bending, and the beam can be formed with even higher accuracy. Therefore, a high-quality bogie frame can be efficiently manufactured. In addition, since the thickness dimensions of the first plate material and the second plate material can be set individually, for example, even when a small amount of reinforcing material is used or no reinforcing material is used, it is easy to manufacture a bogie frame with appropriate strength.

[0053] [Item 3] the at least one first member is a single first member having the plate portion and the protrusion portion, the at least one second member is a single second member; The second member has a pair of first plate portions each having a plate surface that is the plate surface of the second member when viewed from the longitudinal direction, and a second plate portion connecting the pair of first plate portions, forming the beam 2. The manufacturing method of a bogie chassis for a railway vehicle described in item 1, comprising: bringing the plate surfaces of each of the pair of first plate portions of the second member into contact with the side surfaces of the convex portion of the first member, and welding the first member and the second member together in a state in which the plate portions of the first member, the pair of first plate portions of the second member, and the second plate portion of the second member form the closed space.

[0054] According to the method, the beam can be formed using a single first member and a single second member, respectively, so that the number of parts and the amount of welding can be reduced, which reduces the workload for aligning and welding the members together and makes it easier to improve the manufacturing efficiency of the bogie frame.

[0055] [Item 4] Preparing the plate material includes: 2. The method for manufacturing a bogie chassis for a railway vehicle according to claim 1, further comprising: preparing the first member having the plate portion and the protrusion portion both formed by machining.

[0056] According to the method, both the plate portion and the protrusion of the first member can be formed with high precision by machining. This improves the assembly precision of the first member and the second member, and enables high-quality welding. This prevents welding defects and improves the manufacturing efficiency of the bogie frame.

[0057] [Item 5] forming the beam 4. The method for manufacturing a bogie chassis for a railway vehicle according to any one of claims 1 to 3, further comprising full penetration welding of the first member and the second member by bringing the second member into contact with the first member using the convex portion as a backing metal.

[0058] According to the method, when the protruding portion continuous with the plate portion of the first member is welded to the second member from the outside in the width direction of the first member, the protruding portion is used as a backing metal. Therefore, even without using a separate backing metal, the first member and the second member can be welded by full penetration welding by contacting the second member with the first member using the protruding portion as a backing metal. Therefore, welding can be performed appropriately and the number of parts of the bogie frame can be reduced.

[0059] [Item 6] Preparing the plate material includes: The second member has a shape in which a groove exposed to the outside is formed between the first member and the second member; forming the beam 4. The method for manufacturing a bogie chassis for a railway vehicle according to any one of items 1 to 3, further comprising forming a weld bead inside the groove from an outer side in the width direction of the first member.

[0060] According to the method, when manufacturing the bogie frame, by forming a sufficient amount of weld bead inside the groove, the second member can be melted into the first member over the entire region in the thickness direction on the side where the groove of the second member is formed. This allows the first member and the second member to be fully welded. Therefore, the first member and the second member can be welded with high strength. Furthermore, by forming a weld bead inside the groove exposed to the outside, the first member and the second member can be efficiently welded in the longitudinal direction, for example, from the outside in the width direction of the first member. Therefore, the workload related to welding when manufacturing the bogie frame can be further reduced.

[0061] [Item 7] forming the beam 4. The method for manufacturing a rail vehicle bogie chassis according to any one of items 1 to 3, comprising using an automatic welding system including a multi-joint robot having a welding device attached thereto, and a control device that controls the welding device and the multi-joint robot, and controlling the welding device and the multi-joint robot by the control device so as to weld the first member and the second member to each other.

[0062] According to the method, the plate surface of the second member is brought into contact with the side surface of the protrusion, and the first member and the second member are efficiently aligned, and then the first member and the second member can be quickly and stably welded from the outside in the width direction of the first member by an articulated robot equipped with a welding device, thereby further improving the manufacturing efficiency of the bogie frame.

[0063] [Item 8] Equipped with hollow beams, The hollow beam is At least one elongated first member having a plate portion and a protrusion portion that is continuous with the plate portion and protrudes outward from one plate surface of the plate portion when viewed in the longitudinal direction; at least one elongated second member extending in the longitudinal direction of the first member; a welded portion where the first member and the second member are welded together in a state where plate surfaces of the second member are in contact with side surfaces of the protrusion of the first member from both sides in a width direction of the first member; a closed space surrounded by the first member and the second member when viewed from the longitudinal direction.

[0064] According to the above configuration, when manufacturing the bogie frame, the plate surface of the second member is brought into contact with the side surface of the convex portion of the first member, so that the first member and the second member can be quickly aligned while preventing the occurrence of misalignment, as described above, and the alignment work can be reduced. In addition, since the plate portion and the convex portion of the first member are continuous, for example, the work of welding and attaching a separate convex portion to the plate portion can be avoided. In addition, since the first member and the second member can be welded from the outside in the width direction of the first member while the plate surface of the second member is brought into contact with the side surface of the convex portion of the first member, the number of welding points can be reduced compared to the case where welding is performed from both sides of the second member, and the welding work can be performed by utilizing a wide space outside the first member and the second member. This reduces the workload related to the alignment and welding of the members. As a result, the manufacturing efficiency of the bogie frame can be improved.

[0065] [Item 9] The at least one first member includes a pair of first plate members arranged with the plate surfaces facing each other, the at least one second member includes a pair of second plate members arranged with the plate surfaces facing each other, 9. The bogie chassis for a railway vehicle described in item 8, wherein the welded portion includes a portion where the pair of first plate materials and the pair of second plate materials are welded together in a state where the closed space is formed by contacting the plate surfaces of each of the pair of second plate materials with the side surfaces of the convex portions of each of the pair of first plate materials.

[0066] According to the above configuration, the beam is formed using a plurality of members, which is a total of four plate materials including a pair of first plate materials and a pair of second plate materials. Therefore, when manufacturing the bogie frame, for example, a work of forming a beam by bending a plurality of long members is not required. This makes it possible to avoid partial variation in the shape of the members during bending, and the beam can be formed with even higher accuracy. Therefore, a high-quality bogie frame can be efficiently manufactured. In addition, since the thickness dimensions of the first plate material and the second plate material can be set individually, for example, even when a small amount of reinforcing material is used or no reinforcing material is used, it is easy to realize a bogie frame having good strength.

[0067] [Item 10] the at least one first member is a single first member having the plate portion and the protrusion portion, the at least one second member is a single second member; The second member has a pair of first plate portions each having a plate surface that is the plate surface of the second member when viewed from the longitudinal direction, and a second plate portion connecting the pair of first plate portions, Item 9. The bogie chassis for a railway vehicle described in item 8, wherein the welded portion includes a portion where the first member and the second member are welded in a state where the plate surface of each of the pair of first plate portions of the second member contacts the side surface of the convex portion of the first member and the closed space is formed by the plate portions of the first member, the pair of first plate portions of the second member, and the second plate portion of the second member.

[0068] According to the above configuration, the beam can be formed using a single first member and a single second member during manufacturing of the bogie frame, thereby reducing the number of parts and the amount of welding, thereby reducing the workload for aligning and welding the members together and making it easier to improve the manufacturing efficiency of the bogie frame.

[0069] [Item 11] The second member has a shape in which a groove exposed to the outside is formed between the second member and the first member, 11. The bogie chassis for a railway vehicle according to any one of items 8 to 10, wherein the welded portion includes a weld bead disposed from an outer side in the width direction of the first member to an inside of the groove.

[0070] According to the above configuration, when manufacturing the bogie frame, by forming a sufficient amount of weld bead inside the groove, the second member can be melted into the first member over the entire region in the thickness direction on the side where the groove of the second member is formed. This allows the first member and the second member to be fully welded together. Therefore, the first member and the second member can be welded together with high strength. Furthermore, by forming a weld bead inside the groove exposed to the outside, the first member and the second member can be efficiently welded in the longitudinal direction, for example, from the outside in the width direction of the first member. Therefore, the workload associated with welding when manufacturing the bogie frame can be further reduced.

[0071] [Item 12] 11. The bogie chassis for a railway vehicle according to any one of items 8 to 10, wherein a maximum dimension of a thickness of the first member is equal to or greater than a maximum dimension of a thickness of the second member.

[0072] According to the above configuration, by increasing the maximum thickness of the first member to a value equal to or greater than the maximum thickness of the second member, the strength of the hollow beam composed of multiple members can be improved, which can reduce or eliminate the work of welding reinforcing materials to the beam, for example.

[0073] [Item 13] 11. The bogie chassis for a railway vehicle according to any one of items 8 to 10, wherein, as viewed in the longitudinal direction, the protruding portion has an extending portion that extends in the width direction of the first member, and a recessed portion that is recessed in a thickness direction of the plate portion midway along the extending portion.

[0074] According to the above configuration, since the protrusion has an extended portion, the thickness of the first member having the protrusion can be increased, and the strength of the first member can be improved. Also, since the protrusion has a recessed portion, the first member can be made lighter than a member without a recessed portion. Therefore, it is easy to configure a first member with an excellent balance between strength and weight.

[0075] [Item 14] 11. The bogie chassis for a railway vehicle according to any one of items 8 to 10, wherein, when viewed from the longitudinal direction, the plate surface of the second member is in contact with the side surface of the convex portion, and a tip end of the second member in a width direction is in contact with the one plate surface of the plate portion of the first member.

[0076] According to the above configuration, the relative position of the second member with respect to the first member is automatically determined during manufacturing of the bogie frame for a railway vehicle, which makes it possible to improve the dimensional accuracy of the product while omitting a separate process of adjusting the relative position of the second member with respect to the first member. [Explanation of symbols]

[0077] B Weld bead P Hollow beam Q Closed Space R bevel W, Y Work (multiple parts) 1 Automatic welding system 3. Articulated robots 10 Welding equipment 20, 120, 220, 320, 420, 520, 620 First member 20a, 25a, 26a, 120a, 220a, 320a, 425a, 426a, 520a, 620a plate part 20b, 21a, 25b, 26b, 27a, 28a, 120b, 220f, 221a, 302b, 425b, 426b, 427a, 428a plate surface 20c, 25c, 26c, 120c, 220c, 320c, 425c, 426c, 520c, 620c convex part 20d, 25d, 26d, 320d, 425d, 426d side 21, 221, 421 Second member 25, 26, 425, 426 1st plate material 27, 28, 427, 428 2nd plate material 50 Carts 52 Bogie Frame 60 Railroad cars 120e extension part 120f recessed part 220e slope section

Claims

1. Preparing a plurality of members including at least one elongated first member having a plate portion and a protruding portion that is continuous with the plate portion and protrudes outward from one plate surface of the plate portion when viewed in a longitudinal direction, and at least one elongated second member extending in the longitudinal direction of the first member; and welding the first member and the second member together while contacting plate surfaces of the second member with side surfaces of the convex portion of the first member from both widthwise sides of the first member, thereby forming a hollow beam having a closed space surrounded by the multiple members when viewed from the longitudinal direction.

2. the at least one first member includes a pair of first plate members each having the plate portion and the protrusion portion, The at least one second member includes a pair of second plates, forming the beam 2. The manufacturing method for a bogie chassis for a railway vehicle according to claim 1, comprising: arranging the pair of first plate materials with their plate surfaces facing each other, arranging the pair of second plate materials with their plate surfaces facing each other, and contacting the plate surfaces of each of the pair of second plate materials with the side surfaces of the convex portions of each of the pair of first plate materials to form the closed space, and then welding the pair of first plate materials and the pair of second plate materials to form the beam.

3. the at least one first member is a single first member having the plate portion and the protrusion portion, the at least one second member is a single second member; The second member has a pair of first plate portions each having a plate surface that is the plate surface of the second member when viewed from the longitudinal direction, and a second plate portion connecting the pair of first plate portions, forming the beam 2. The manufacturing method of a bogie chassis for a railway vehicle according to claim 1, comprising: bringing the plate surfaces of each of the pair of first plate portions of the second member into contact with the side surfaces of the convex portion of the first member, and welding the first member and the second member together in a state in which the plate portions of the first member, the pair of first plate portions of the second member, and the second plate portion of the second member form the closed space.

4. Preparing the plate material includes: The method for manufacturing a bogie chassis for a railway vehicle according to claim 1 , further comprising: preparing the first member having the plate portion and the protrusion portion both formed by machining.

5. forming the beam 4. The manufacturing method of a bogie chassis for a railway vehicle according to claim 1, further comprising full penetration welding of the first member and the second member by bringing the second member into contact with the first member using the convex portion as a backing metal.

6. Preparing the plate material includes: The second member has a shape in which a groove exposed to the outside is formed between the second member and the first member, forming the beam 4. The method for manufacturing a bogie chassis for a railway vehicle according to claim 1, further comprising forming a weld bead inside the groove from an outer side in the width direction of the first member.

7. forming the beam 4. The method for manufacturing a bogie chassis for a railway vehicle according to claim 1, further comprising: using an automatic welding system including a multi-joint robot having a welding device attached thereto, and a control device that controls the welding device and the multi-joint robot, and controlling the welding device and the multi-joint robot by the control device so as to weld the first member and the second member to each other.

8. With hollow beams, The hollow beam is At least one elongated first member having a plate portion and a protrusion portion that is continuous with the plate portion and protrudes outward from one plate surface of the plate portion when viewed in the longitudinal direction; at least one elongated second member extending in the longitudinal direction of the first member; a welded portion where the first member and the second member are welded together in a state where plate surfaces of the second member are in contact with side surfaces of the protrusion of the first member from both sides in a width direction of the first member; a closed space surrounded by the first member and the second member when viewed from the longitudinal direction.

9. The at least one first member includes a pair of first plate members arranged with the plate surfaces facing each other, The at least one second member includes a pair of second plate members arranged with the plate surfaces facing each other, 9. The bogie frame for a railway vehicle according to claim 8, wherein the welded portion includes a portion where the pair of first plate materials and the pair of second plate materials are welded together in a state where the closed space is formed by contacting the plate surfaces of each of the pair of second plate materials with the side surfaces of the convex portions of each of the pair of first plate materials.

10. the at least one first member is a single first member having the plate portion and the protrusion portion, the at least one second member is a single second member; The second member has a pair of first plate portions each having a plate surface that is the plate surface of the second member when viewed from the longitudinal direction, and a second plate portion connecting the pair of first plate portions, 9. The bogie chassis for a railway vehicle according to claim 8, wherein the welded portion includes a portion where the first member and the second member are welded together in a state in which the plate surface of each of the pair of first plate portions of the second member contacts the side surface of the convex portion of the first member, and the closed space is formed by the plate portions of the first member, the pair of first plate portions of the second member, and the second plate portion of the second member.

11. The second member has a shape in which a groove exposed to the outside is formed between the second member and the first member, The bogie chassis for a railway vehicle according to any one of claims 8 to 10, wherein the welded portion includes a weld bead arranged inside the groove from an outer side in the width direction of the first member.

12. The bogie chassis for a railway vehicle according to any one of claims 8 to 10, wherein a maximum dimension of a thickness of the first member is equal to or greater than a maximum dimension of a thickness of the second member.

13. 11. The bogie chassis for a railway vehicle according to claim 8, wherein, when viewed from the longitudinal direction, the convex portion has an extending portion that extends in the width direction of the first member, and a recessed portion that is recessed toward a thickness direction of the plate portion midway along the extending portion.

14. 11. The bogie chassis for a railway vehicle according to claim 8, wherein, when viewed from the longitudinal direction, the plate surface of the second member is in contact with the side surface of the convex portion, and a widthwise tip of the second member is in contact with the one plate surface of the plate portion of the first member.

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