Rail Car Air Treatment Interface Module for Faster Assembly
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Solution Overview
Problem
The assembly of air treatment units to double-deck rail vehicles is time-consuming due to access difficulties and the need for individual through ducts, which complicates the integration of bulky pre-assembled modules into the car body.
Innovation Solution
A pre-assembled interface module with a large opening in the upper end wall of the rail vehicle car body, featuring a mounting plate and through ducts that seal and connect the air treatment unit to the interior space, allowing for the easy insertion of bulky modules and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual through ducts are used to connect the air treatment unit to the interior space, then the air treatment connection is achieved, but the assembly process becomes time-consuming and tedious due to access difficulties
Solution Approach 1:
The patent combines multiple individual through ducts into a single integrated through duct assembly that is pre-assembled with the air treatment unit. This merging of multiple separate connection components into one unified module eliminates the need for individual installation of each duct, significantly reducing assembly time and improving ease of manufacture while maintaining all necessary air treatment connections.
Solution Approach 2:
The through ducts are pre-assembled and pre-positioned relative to the air treatment unit before the final installation in the vehicle. This preliminary action allows the complex ductwork to be prepared in advance with proper routing and connections, eliminating time-consuming on-site assembly work and improving the overall manufacturing efficiency of the vehicle assembly process.
2Ease of operation
If a large opening is provided in the upper end wall for inserting bulky modules, then the insertion of pre-assembled interior fittings is facilitated, but the opening requires a complex sealing solution
Solution Approach 1:
The mounting plate integrates multiple functions into a single component: it serves as the sealing element for the large opening, provides structural support for the through ducts, and acts as the connection interface for the air treatment unit. This merging of sealing, structural, and connection functions into one integrated mounting plate simplifies the overall sealing structure while facilitating the insertion of bulky pre-assembled modules.
3Volume of moving object
If the air treatment unit is positioned on top of the lower roof section facing the upper end wall, then space utilization is optimized, but access for assembly becomes difficult
Solution Approach 1:
The air treatment unit is pre-assembled with the through ducts and mounting plate in a ground-level facility where full access is available. This preliminary assembly action allows workers to easily connect all components and perform quality checks before the entire assembly is lifted into the vehicle. The pre-assembly eliminates the need for difficult on-site assembly work in the confined space on top of the lower roof section, while still achieving optimal space utilization in the final vehicle configuration.
Data Source
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AI summary
A double-deck car body (10) of a rail vehicle comprises an upper end wall (24) facing a lower roof section (20) at an end of an upper deck (16) of the double-deck car body (10). The upper end wall (24) is provided with an opening (26) having a maximal width larger than 1m, preferably larger than 1,2 m and a maximal height larger than 0,5 m, preferably larger than 0,8 m. An air treatment unit (32) is located on top of the lower roof section (20) and faces at a distance the upper end wall (24) and the opening (26). An interface module (40) comprises a mounting plate (42) shaped to fit over a peripheral edge of the opening (26) so as to close and seal the opening (26), and through ducts (48, 50) tightly passing through the mounting plate (42) for connecting the air treatment unit (32) to an interior space (12) of the double-deck car body (10).