Rail Vehicle Body Shell Assembly Using Structural Adhesive Bonding

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Solution Overview

Problem

Existing methods for producing rail vehicle car body shells are time-consuming and costly due to welding requirements, which also limit material diversity and are prone to thermal deformations, and do not allow for the use of different materials in major assemblies.

Innovation Solution

The method involves joining large assemblies of the car body shell using structural bonding, allowing for differential or integral construction, and utilizing hollow chamber profiles with threading devices and structural adhesives to form a flush outer skin, enabling the use of materials like fiber-reinforced plastic.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to join large assemblies of the car body shell, then the structural strength and rigidity are improved, but the production time and cost increase due to straightening and post-processing steps

Engineering Contradiction:

Improvestructural strengthVSAvoidproduction time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical joining method) with structural bonding using adhesives. This substitution eliminates the need for post-welding straightening and post-processing operations, thereby reducing production time while maintaining structural integrity through chemical bonding mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the joining parameter from thermal welding to chemical bonding. By using structural adhesives with specific bonding parameters (surface preparation, adhesive application, curing conditions), the process achieves comparable or superior structural strength without the time-consuming thermal cycles and post-processing required by welding.

Inventive Principle:

Principle #35Parameter changes

2Strength

If welding is used to join large assemblies of the car body shell, then the structural strength and rigidity are improved, but the production cost increases due to straightening and post-processing steps

Engineering Contradiction:

Improvestructural strengthVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process with structural bonding, eliminating expensive post-welding operations such as straightening, grinding, and inspection. This substitution reduces production costs while maintaining structural strength through properly engineered adhesive bonding systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If welding is used to join large assemblies of the car body shell, then the structural strength is improved, but the material diversity is limited as different materials cannot be used for various major assemblies

Engineering Contradiction:

Improvestructural strengthVSAvoidmaterial diversity

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent employs structural adhesives as a universal joining method that can bond dissimilar materials (metal to metal, metal to composite, composite to composite) that cannot be welded together. This universality enables material diversity in different car body assemblies while maintaining overall structural strength through the adhesive bonding system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Strength

If welding is used to join large assemblies of the car body shell, then the structural strength is improved, but thermal deformations occur during the welding process

Engineering Contradiction:

Improvestructural strengthVSAvoiddimensional accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the thermal welding process with cold structural bonding, eliminating the thermal cycles that cause expansion, contraction, and distortion. This substitution preserves dimensional accuracy and manufacturing precision throughout the assembly process while achieving the required structural strength through adhesive bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces the need for straightening and post-processing, allows for diverse materials, and provides a more efficient and cost-effective production method for rail vehicle car body shells.

Implementation Method 1

The large assemblies are joined together by means of structural bonding

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP4232339B1Process for the modular manufacturing of rough bodywork of a rail vehicle, and rough bodywork

Publication Date: 2025.11.19 SIEMENS MOBILITY GMBH

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AI summary

The invention relates to a process for the modular manufacturing of rough bodywork (7) of a rail vehicle, involving the consecutive steps of: a) making at least two immediately adjoining large assemblies (4, 5, 6) of the rough bodywork (7) in parallel, said large assemblies being selected from among the group consisting of an underframe, a side wall, a roof, an end wall, and a body end; b) joining the at least two large assemblies (4, 5, 6) made in parallel in step a) using structural adhesive bonding. Also disclosed is rough bodywork of a rail vehicle manufactured by said process.