Railway Bodyshell Interlocking Fixing Means Eliminating Shaper Tools
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Solution Overview
Problem
The existing modular railway vehicle body assembly methods require expensive and bulky shapers for positioning modules, leading to high assembly costs, long production times, and storage challenges due to the need for custom-made tools for each design and dimension.
Innovation Solution
The modular railway vehicle body employs interlocking profiles with complementary fixing means on the frame, roof, and face panels, allowing for adjustment and stiffening without a shaper, using bolts or rivets through coaxial drillings for assembly, enabling the elimination of shaper tools and reducing assembly time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a shaper is used to position modules during assembly, then positioning precision is improved, but manufacturing cost increases and assembly time is extended
Solution Approach 1:
The fixing means are segmented into complementary male and female sections with interlocking profiles. The male section protrudes while the female section receives it, creating modular positioning elements that can be independently manufactured and assembled without requiring a large integrated shaper tool.
Solution Approach 2:
The interlocking profiles provide self-positioning capability during assembly. The complementary shapes automatically guide and constrain the relative positioning of modules as they are brought together, eliminating the need for external positioning equipment like shapers.
2Manufacturing precision
If a shaper is used to position modules, then positioning precision is improved, but manufacturing cost increases
Solution Approach 1:
The fixing means are divided into separate male and female sections that can be manufactured independently using standard machining processes. This segmentation eliminates the need to manufacture expensive, custom-made shaper tools for each assembly task.
Solution Approach 2:
The interlocking profile components are designed as simple, inexpensive elements that can be easily manufactured and replaced if needed. These replace expensive, durable shaper tools with cheaper, simpler fixing elements that achieve the same positioning function.
3Manufacturing precision
If custom shapers are made for each design and dimension, then positioning accuracy is improved, but storage requirements increase and device complexity increases
Solution Approach 1:
The complementary interlocking profiles are designed as universal fixing means that can accommodate different module designs and dimensions. The same male and female section concepts can be applied across various vehicle body configurations, eliminating the need for multiple custom shaper tools.
Solution Approach 2:
The fixing means can be adapted to different designs and dimensions by modifying parameters such as profile geometry, size, and distribution, rather than creating entirely new shaper tools. This allows a single fixing concept to serve multiple applications.
Data Source
Figure 1
Figure 2~3
Figure 4a~4c
AI summary
The body has a chassis (2) and a roof that are provided with fixation units on longitudinal edges. Front panels (3) are provided on upper and lower edges of third fixation unit (11) and fourth fixation unit respectively cooperating with the former fixation units. The four fixation units have complementary interlocking sections. The sections are arranged to hold the front panels with respect to the chassis and the roof with an adjusting clearance for permitting a relative displacement of the front panels with respect to the chassis and the roof. An independent claim is also included for a method for fabricating a body for a rail transit car.