Railway Module Assembly Using Pre-Drilled Holes and Blind Rivets
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Solution Overview
Problem
The assembly of railway vehicle bodies through welding or riveting often results in deformation and requires complex assembly stations, leading to inefficiencies and suboptimal assembly quality.
Innovation Solution
A method involving pre-equipped modules with digitally modeled and precisely drilled fixing holes, allowing for the use of numerically controlled machine tools to drill holes with high accuracy, followed by the assembly of modules using one-piece blind rivets that simplify the assembly process and eliminate chip production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect modules, then assembly strength is improved, but module deformation occurs
Solution Approach 1:
The patent replaces welding (thermal-chemical process) with blind riveting (mechanical fastening process). The blind rivets provide sufficient mechanical connection strength while avoiding the heat-affected zone deformation caused by welding. The rivets are inserted through pre-drilled holes and deformed to create secure mechanical joints without thermal influence on the module structure.
2Manufacturing precision
If pre-drilling rivet holes during module assembly is done, then assembly precision is improved, but assembly station complexity increases and chip production occurs
Solution Approach 1:
The patent applies preliminary action by pre-drilling rivet holes in modules during the manufacturing phase before assembly. The holes are drilled with precise positioning (within 0.5mm tolerance) using dedicated drilling equipment, then modules are assembled without requiring complex real-time positioning systems. This separates the precision drilling operation from the assembly operation, simplifying the assembly station while maintaining high precision.
3Manufacturing precision
If oblong rivet holes are created prior to module assembly, then positioning tolerance is improved, but assembly station complexity increases and assembly quality decreases
Solution Approach 1:
The patent applies local quality by using small, precisely positioned circular holes (5-10mm diameter) rather than large oblong holes. The high precision drilling equipment ensures these small holes are positioned accurately within 0.5mm tolerance, providing sufficient positioning accuracy without requiring the larger clearance of oblong holes. This eliminates the need for complex assembly station fixtures while maintaining assembly quality.
4Manufacturing precision
If complex assembly stations are used for riveting, then assembly precision is improved, but assembly time increases
Solution Approach 1:
The patent uses preliminary action by pre-drilling all rivet holes during module manufacturing before assembly. This preliminary precision drilling eliminates the need for complex real-time positioning and adjustment mechanisms during assembly. The pre-positioned holes allow for rapid module assembly using simple fixtures, significantly reducing assembly time while maintaining high precision through the pre-established hole positions.
Data Source
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AI summary
This assembly process comprises the following steps: - creation of a digital model of at least one specific module (76); - dimensioning in the digital model the position of fixing holes (60) in the specific module (76), the dimensioning of each fixing hole (60) being defined at least with respect to an edge of the specific module (70) extending along a direction of greatest length (B-B') of the specific module (76) and with respect to a transverse axis (X-X') to the direction of greatest length (B-B'); - supply of the specific module (76); - drilling the fixing holes (60) in the specific module (76) by means of a drilling device at the position dimensioned in the digital model; and - assembly of the casing, said assembly comprising the fixing of the specific module (76) to at least one adjacent module by means of fixing members inserted into the fixing holes (60) drilled in the specific module (76).