Method for connecting a connection piece to a u-shaped ring anchor for a head module for rail vehicles

Abstract

The invention relates to a method for connecting a connection piece to a U-shaped ring anchor for a head module for rail vehicles, the head module consisting predominantly of fiber-reinforced plastic material and having an outer shell and the ring anchor consisting of fiber-reinforced plastic material and being arranged in the roof region of the outer shell as a stiffening means. According to the method, connecting elements are fed through the dry or matrix-material-impregnated, unconsolidated fiber reinforcement structure of the ring anchor.

Claims

1. A method for connecting a connection piece to a U-shaped ring beam for a head module for rail vehicles, wherein the head module consists predominantly of fibre-reinforced plastic material and has an outer shell, and the ring beam consists of fibre-reinforced plastic material and is arranged as stiffener in a roof area of the outer shell, having at least the following steps: a) preparing a mould for the outer shell with a section mould for the ring beam, b) preparing a fibre-reinforcing structure of the ring beam which structure is dry or impregnated with matrix material and unconsolidated, and placing it in the section mould, c) preparing the connection piece for each end of the U-shaped ring beam, d) preparing connecting elements, e) feeding the connecting elements through the fibre-reinforcing structure of the ring beam or construction in plies of the fibre-reinforcing structure, wherein each ply is deposited while being penetrated by the connecting elements, f) feeding the connecting elements through openings of the connection pieces provided for this purpose, g) constructing the outer shell from fibre-reinforcing material and impregnating the fibre-reinforcing material of outer shell and ring beam with matrix material, h) jointly consolidating ring beam and outer shell, i) fixing the connecting elements such that they are fixed on both sides of the ring beam, including the connection pieces.

2. The method according to claim 1, wherein step b) is realized by the construction of the fibre-reinforcing structure, which is dry or impregnated with matrix material, of the ring beam in the section mould.

3. The method according to claim 1, wherein the section mould is represented by a suitably milled core.

4. The method according to claim 1, wherein step b) is effected by the construction of the fibre-reinforcing structure, which is dry or impregnated with matrix material, of the ring beam in a mould outside of the mould for the outer shell.

5. The method according to claim 1, wherein the connection pieces are placed in the section mould before step b).

6. The method according to claim 1, wherein step c) and step d) are effected jointly in that the connecting elements are prepared as part of the connection pieces.

7. The method according to claim 1, wherein step d) includes a fitting of a tip on each connecting element to support the penetration of fibre plies.

8. The method according to claim 7, wherein the tip of each connecting element is removed after step h).

9. The method according to claim 1, wherein step d) includes a fitting of a casing in an area of the connecting elements which comes into contact with the material of the ring beam.

10. The method according to claim 9, wherein the casing remains as internal thread in the ring beam after the connecting element is removed.

11. The method according to claim 1, wherein a section of the connection piece is also fixed in step i).

12. The method according to claim 2, wherein the connection pieces are placed in the section mould before step b).

13. The method according to claim 2, wherein step c) and step d) are effected jointly in that the connecting elements are prepared as part of the connection pieces.

14. The method according to claim 2, wherein step d) includes a fitting of a tip on each connecting element to support the penetration of fibre plies.

15. The method according to claim 14, wherein the tip of each connecting element is removed after step h).

16. The method according to claim 2, wherein step d) includes a fitting of a casing in an area of the connecting elements which comes into contact with the material of the ring beam.

17. The method according to claim 16, wherein the casing remains as internal thread in the ring beam after the connecting element is removed.

18. The method according to claim 2, wherein a section of the connection piece is also fixed in step i).

Description

(1) The following figures illustrate the fixing of connection pieces on the ends of a ring beam for the head module of a rail vehicle by way of example.

(2) FIG. 1 shows a schematic side view of the cab without the outer shell. The central buffer coupling has also been omitted for the sake of clarity. The inner shell 701 is designed in two parts. The division occurs in the horizontal plane above the railing reinforcement 711. The upper part of the inner shell 701 comprises the opening 704 for the front window and the side windows 703. The window openings are separated from each other by the A pillar 705. Above the upper part of the inner shell the ring beam 720 is represented. It is detachably fixed to the upper longitudinal beams of the following coach section (not represented) via the connection piece 721.

(3) The railing reinforcement 711 and the UD braces 710 which transmit the force from the railing reinforcement 711 to the introduction points 712 into the lower longitudinal beams of the following coach section are integrated into the lower part of the inner shell.

(4) The lower crash conduction element 730 runs underneath the lower part of the inner shell. On the front side of the cab the plate 734 is represented. The crash box 733 is arranged behind it. In the event of a crash, the collision takes place on the plate 734 which passes the force onto the crash box 733 and dissipates it as far as possible there. Remaining impact energy is passed on into the lower crash conduction element 730 and there is transferred at the fixing point 732 into the underframe support of the following coach section. In the horizontal section of the lower crash conduction element 730, the openings 731 for fixing the central buffer coupling are visible.

(5) FIG. 2 shows the schematic front view of the cab without the outer shell. Compared with the side view from FIG. 1, the cover flap of the central buffer coupling with the reference number 706 is additionally provided, which fits into a corresponding opening in the outer shell.

(6) FIG. 3 shows the schematic rear view of the inner shell of the cab. This is the side with which the cab is installed on the following coach section. The installation is preferably effected on the two upper longitudinal beams of the following coach section by means of the connection pieces 721 of the upper ring beam, by means of the fixing elements at the introduction points 712 of the UD braces from the railing reinforcement and by means of the fixing device 712 (only one is represented, a second is arranged symmetrically on the right-hand side) of the lower crash element on the underframe support.

(7) FIG. 4 shows a schematic three-dimensional view of the outer shell 702. In particular, it can be seen how the upper ring beam 720 with its connection pieces 721 fits into the outer shell 702. The opening for the cover flap 706 of the central buffer coupling is also represented.

(8) FIG. 5 shows, schematically, the structure of the ring beam 720 with the two connection pieces 721. The connection pieces 721 are connected to the ring beam via connecting elements through the openings 7214. They have the installation openings 7217 through which the ring beam is connected to the following coach section via the connection pieces and the front section 7213. For this, connecting elements, in particular screws, are fed through the openings 7216, which can be tightened through the installation opening 7217. The openings 7215 optionally allow a screw connection to the outer shell.

(9) FIG. 6 shows, schematically, an embodiment of the connection piece 721. This connection piece has a lower section 7211, an upper section 7212 and the front section 7213. The sections consist of steel and are fixed to one another by means of welded joints.

(10) FIG. 7 shows, schematically, the connection piece according to FIG. 6 from a different perspective.

(11) FIG. 8 shows, schematically, the connection piece according to FIG. 6 from below.

(12) FIG. 9 shows, schematically, an embodiment for a connecting element 740 with a section through the screwed-on tip 751 and the casing 7503. The connecting element has the shape of a screw and consists of a head section 7402 and a body 7401 with a thread. It has no thread in the section which comes into contact with the matrix material after installation. The casing 7503, which prevents direct contact between the metallic connecting element and the reinforcing fibre structure, is arranged there. The casing remains in the fully consolidated and installed ring beam. The tip 751 has a pointed section 7501 which is screwed onto the thread 7502. After the fibre composite material is consolidated, the tip is unscrewed and the nut for fixing the connecting element is screwed onto the thread 7502, and a washer or a further section of the connection piece optionally placed underneath.

LIST OF REFERENCE NUMBERS

(13) 701 inner shell 702 outer shell 703 side window opening 704 front window opening 705 A pillar 706 cover flap of the central buffer coupling 707 internal fittings 710 UD brace of the railing reinforcement 711 railing reinforcement 712 introduction point of the forces from the railing reinforcement into the lower longitudinal beam of the following coach 720 ring beam 721 connection piece 7211 lower section 7212 upper section 7213 front section 7214 openings 7215 openings 7216 openings 7217 installation openings 730 lower crash conduction element 7301 section of the crash conduction element from the crash box to the horizontal section 7302 horizontal section 7303 section of the crash conduction element from the horizontal section to the fixing element on the underframe support 731 holes for fixing the central buffer coupling 732 fixing device of the lower crash element on the underframe support 733 crash box 734 plate 740 connecting bolts for fixing the connection piece to the ring beam 7401 bolt body 7402 bolt head 750 tip for supporting the penetration of the fibre-reinforcing material 7501 pointed section 7502 thread 7503 casing of the connecting bolt