WORK VEHICLE FOR CARRYING OUT WORK OPERATIONS ON A TRACK

Abstract

The invention relates to a work vehicle for carrying out work operations on a track, comprising a vehicle frame which can be moved on the track supported on rail running gears, a drive cab which is connected to the vehicle frame, and various mounted structures with assigned functions for a work operation. The mounted structures are designed as self-supporting function modules with predefined interfaces and connected to the vehicle frame and/or each other by means of threaded connections. The predefined interfaces enable the interconnection of different function modules without further adaptations. All modules are continuously checked with regard to their geometry and their functions to enable joinability in the final assembly without welding and adjustment processes.

Claims

1. A work vehicle for carrying out working operations on a track, comprising a vehicle frame which can be moved on the track supported on rail running gears, a drive cab which is connected to the vehicle frame, and various mounted structures with assigned functions for a work operation, wherein the mounted structures are designed as self-supporting function modules with predefined interfaces and connected to the vehicle frame and/or each other by means of threaded connections.

2. The work vehicle according to claim 1, wherein mechanical, and electrical, and/or hydraulic, and/or pneumatic interfaces are predefined.

3. The work vehicle according to claim 1, wherein the predefined interfaces comprise joining elements which enable an adjustment of the respective function module, in particular, in two directions orthogonal to each other.

4. The work vehicle according to claim 1, wherein the predefined interfaces comprise joining elements that have a unique geometric fit to each other.

5. The work vehicle according to claim 1, wherein the vehicle frame comprises two lateral longitudinal carriers, the upper edges of which span a vehicle floor, and in that at least one function module is arranged as an underfloor module below the vehicle floor.

6. The work vehicle according to claim 5, wherein the respective longitudinal carrier comprises a longitudinal-carrier upper flange and a longitudinal-carrier lower flange, which are connected to one another by a plurality of connecting elements arranged at equal distances from one another.

7. The work vehicle according to claim 5, wherein an underfloor module is designed as a traction module and in that the traction module comprises an internal combustion engine coupled to a generator and/or a pump distributor gearbox.

8. The work vehicle according to claim 1, wherein at least one function module is designed to be shiftable on guides in relation to the vehicle frame.

9. The work vehicle according to claim 8, wherein the shiftable function module is fastened to an auxiliary frame.

10. The work vehicle according to claim 1, wherein the vehicle frame is divided into three sections in the longitudinal direction, in that the drive cab is arranged on one end section, in that a crane module or a further cab is arranged on the other end section, and in that further function modules are set up on the middle section.

11. The work vehicle according to claim 1, wherein an assembly space for the assembly of the function modules, which is predefined by the dimensions of the vehicle frame and by a clearance gauge to be maintained, is divided into a plurality of segments in the vertical direction, in the longitudinal direction, and in the transverse direction.

12. The work vehicle according to claim 1, wherein a modular control software is set up in a control device, in that different function modules are assigned their own software modules, and in that the software modules are able be enabled separately.

13. The method for assembling a work vehicle according to claim 1, wherein the vehicle frame is manufactured with a dimensioning adapted to selected function modules, in that each function module is initially pre-assembled as a self-supporting unit, and in that the pre-assembled function modules are bolted to the vehicle frame and/or to each other.

14. The method according to claim 13, wherein the respective pre-assembled function module is put into operation before installation by means of a diagnostic device.

15. A method according to claim 13, wherein a modular control software set up in a control device is adapted to the installed function modules.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In the following, the invention is explained by way of example with reference to the accompanying figures. The following figures show in schematic illustrations:

[0026] FIG. 1 Vehicle frame in a top view

[0027] FIG. 2 Vehicle frame in a side view

[0028] FIG. 3 Cross-section of the vehicle frame

[0029] FIG. 4 Vehicle cross-section

[0030] FIG. 5 Diagnostic device

[0031] FIG. 6 Vehicle concept in a side view and a top view

[0032] FIG. 7 Different vehicle configurations

[0033] FIG. 8 Vehicle configuration with crane and lifting platform

[0034] FIG. 9 Traction module with generator

[0035] FIG. 10 Traction module with pump distributor gear box

DESCRIPTION OF THE EMBODIMENTS

[0036] FIGS. 1-3 show an exemplary vehicle frame 1 for a work vehicle 2 based on a modular design kit system. The main elements of the vehicle frame 1 are two lateral longitudinal carriers 3, each having an upper flange 4 and a lower flange 5. The respective upper flange 4 and the associated lower flange 5 are connected by means of connecting elements (struts) 6, which are arranged at equal distances from each other in a longitudinal direction of the vehicle 7. This provides a standardized scaling of the vehicle frame 1 to be able to manufacture it with different lengths.

[0037] The vehicle frame 1 is divided into two end sections 8 and an intermediate middle section 9. In each end section 8, the longitudinal carriers 3 are rigidly connected to a transverse carrier 10. Pivots and supports for rail running gears 11 in modular design are arranged on these transverse carriers 10. Optionally, another transverse carrier 10 is positioned in the middle section 8 as a support for a crane module 12. The position of this transverse carrier 10 is freely selectable in the longitudinal direction 7 along the scaling predefined by the connecting elements 6. In particular, the respective lower flange 5 is only arranged in the middle section 9.

[0038] According to the invention, the dimensioning of the vehicle frame 1 is adapted to selected function modules 11-22. This selection is derived from predefined vehicle requirements. A module catalogue is created in a design phase carried out in advance in which each function module 11-22 is defined with all functions and predefined interfaces 23. Subsequently, all possible function modules 11-22 and their possible combinations are defined in order to fulfil the requirements specifications. Positioning conditions and compliance with operational limits are determined (clearance gauge, track gauge, line category, standards, and laws). Exclusion criteria for impossible combinations are also defined. Advantageously, a computer-implemented module configurator uses a corresponding algorithm. This means that function modules 11-22 and machine functions can be combined automatically, taking into account the operational limits, the technical service life, and the excluding criteria. This automated module configuration also takes country-specific conditions into account. The module configurator can be expanded with a cost calculation algorithm to provide a cost and price design kit. In addition, a virtual configuration of the vehicle 2 by a CAD algorithm for selecting module combinations from a module library is useful.

[0039] The function modules 11-22 standardized in this way can be combined with each other according to a design kit system and are partially scalable in size and range of functions. In addition to a rail running gear module 11 and a crane module 12, for example, a lifting platform module 13, a traction module (power pack) 14, a tank module 15, an overhead line and energy supply module 16, a workshop module 17, a social cab module 18, a technical room module 19, a loading area module 20 as well as a drive cab 21 and various other modules 22 can be selected as function modules. Modules 11-22 are scalable, in particular, according to customer-specific requirements. For example, load capacities and jib reaches of cranes can be varied.

[0040] Each of these function modules 11-22 is designed as a self-supporting unit with predefined interfaces 23. A lightweight construction method is used to reduce the vehicle weight and to increase the number of attachable modules 11-22, taking into account the maximum permissible axle load and the respective line category. For example, the cabs 17, 18, 19, 21 are manufactured from a wrought aluminium alloy. Laser-cut and folded aluminium sheets with a thickness of 5 mm to 10 mm are installed in a spade construction method. In addition, the use of high-strength fine-grain structural steels results in a reduction of the material thicknesses and the vehicle weight.

[0041] Depending on the function of the respective module 11-22, the predefined interfaces 23 comprise mechanical, electrical, hydraulic, pneumatic, and other connections. In particular, data interfaces are provided for communication with other modules 11-22 and with a central control device 24. Individual modules such as the traction module 14 are preferably mounted on an auxiliary frame 25. All relevant components for the respective function unit are combined in a spatially compact manner. The function module 11-22 set up in this way is easy to transport and can be positioned and mounted with a crane or a lifting device. A high level of detail in the design and the unambiguous construction method enable a prefabrication of the function modules 11-22 at different production sites. A continuous change management ensures history tracking. In addition, there is a standardized retrofit and upgrade management for ongoing technical updating and for standard-compliant adaptation of existing vehicles to ensure a long-term service life.

[0042] For a new vehicle 2, a basic type and a drive concept are first defined. For example, a choice is made between two single axles and two bogies as basic rail running gears 11. A basic vehicle 2 consists of two rail running gears 11, the vehicle frame 1 with integrated modules for traction and driving, a drive cab 21 with the vehicle control system, and a workstation for the driver that conforms to standards as well as free spaces for function modules 11-22. The minimum configuration of modules 11-22 is also specified for the representation of the basic functions of driving and parking. All function modules 11-22 can be used for both a two-axle and a four-axle platform.

[0043] The vehicle frame 1 serves as a platform on which the function modules 11-22 selected from the modular design kit system are set up during final assembly. The upper flange 4 is a standardized main carrier with defined interfaces in the longitudinal direction 7. On each side there is a free space 26 between the upper flange 4 and the lower flange 5 for maintenance components. Cable cups 27 are arranged on the outside along the entire length of the vehicle. The upper edges of the longitudinal carriers 3 span a vehicle floor 28, which divides an assembly space into an upper and a lower area. As can be seen in FIG. 3, there is a free space 29 between the longitudinal carriers 3 for an underfloor assembly. The optional middle transverse carrier 10 and the connecting elements 6 have openings for a line routing. Preferably, the line routing is positioned laterally in the area of the lower flanges and offers space for a cable harness, for hydraulic and pneumatic lines. The design of the standardized function modules 11-22 allows a variable assembly location on the base frame 1.

[0044] The assembly of the work vehicle 2 is explained with reference to FIGS. 4-6. First, a distinction is made between the underfloor assembly space 29 and an overfloor assembly space 30. The traction modules 14 for operating the vehicle 2 are preferably arranged underfloor (e.g. bogies, power pack, transformer, accumulators, etc.). The traction module 14 comprises, for example, an engine, a generator, an electric drive, and, if applicable, a braking energy recuperator. In addition, the traction module 14 is coupled to overhead line energy supply modules 16. Additionally, for example, accumulators, fuel cells, and other new energy sources (solar plant) are arranged.

[0045] On the vehicle floor 28, for example, the technical room 19, drive cabs 21, electrical switch cabinets, crew cabs 18, workshop 17, crane 12, and lifting platform 13 are arranged. Buffers and coupling devices are provided at a front area 31 and at a tail area 32. This allows trailers to be coupled or a plurality of vehicles 2 to be coupled together. In addition, it is possible to attach add-on modules 22 for special functions (snow removal equipment, measuring devices, etc.). On the roof of the cabs 21 there is space for roof-mounted structures 16 (e.g. current collectors, brake resistors, lines, etc.).

[0046] In the vertical direction 33, the modules 11-22 are mounted in four segments one above the other. Starting from the bottom, the 1st segment comprises e.g. rail running gears 11. The 2nd segment between lower flange 5 and upper flange 4 is used, for example, to accommodate the traction module (power pack) 14, a transformer module, an accumulator module, and a tank module 15. In the 3rd segment, for example, cabs 21, a crane module 12, and a lifting platform module 13 can be arranged above the vehicle floor 28. The 4th segment on the roof comprises, for example, current collectors, brake resistors, and various tools such as line pushers.

[0047] In the transverse direction 34, the modules 11-22 are preferably assembled in three segments. On the left and right outside, for example, maintenance shafts are arranged for line routing. In between is a segment for the function units.

[0048] In the longitudinal direction 7, there is a subdivision into up to ten segments. In these segments, for example, buffers and draw hooks, the drive cab 21, the social cab 18, the workshop cab 17, the lifting platform 13, the loading platform 20, a tool room, the crane 12, a crane cab, and again buffers and draw hooks are arranged one behind the other.

[0049] FIG. 6 shows a variation of the assembly position of a function module 11-22 in the vertical direction 33, longitudinal direction 7, and transverse direction 34. For example, a tank module 15 is mounted on an auxiliary frame 25. Then shifting the tank module 15 sideways on the auxiliary frame 25 allows a change of the assembly position in the transverse direction 34. A change of the assembly position in the longitudinal direction 7 is made by shifting the auxiliary frame 25 on the vehicle frame 1 along guides. In the vertical direction 33, a shifting of the module 15 along the connecting elements 6 between upper and lower flange 4, 5 causes a change of the assembly position.

[0050] Before the final assembly of the modules 11-22, a module diagnosis is carried out. Modules that have been checked in this way are joined together in a way similar to a building block principle and connected with a positive and friction fit. The same applies to the assembly of the lines and the additional devices. The positional orientation and positioning is clearly predefined and constrained, for example, by matched shaping. Each joining process is checked with a checklist and accepted and confirmed during a worker self-check. The system functions are checked and verified by a machine evaluation after joining the modules 11-22 and the connecting lines.

[0051] As part of the module diagnosis, a quantitative measurement and assessment of the individual modules 11-22 and a qualitative evaluation of the functional systems for the final assembly is carried out. For example, the following checks are carried out on a traction module (power pack) 14: [0052] Electrical input and output measurement [0053] Electrical analysis of the signals [0054] Checking the media flow: fuel, cooling water, additives, cooling air flow [0055] Hot measurement of a combustion engine 37: load-free speed ramp-up with current measurement (transient) [0056] Test program for checking a control program (I/O check and actuator check) [0057] Weight measurement and photo documentation [0058] Scanning of data matrix codes, etc. [0059] Special measurement of vibration and noise emission and particle counter [0060] Validation checklist for e.g. visual inspection and test sequence [0061] Test marking (good/bad, rework)

[0062] A universal diagnostic device 38, shown schematically in FIG. 5, is set up to check all modules 11-22. On a set-up station there is a delivery zone, a mobile transport device with module fastening, a lifting device, and assembly tools. The diagnostic device 38 itself is a universal measuring and testing device with mechanical fastening elements adapted to mechanical interfaces of the modules 11-22; with its own energy supply; with a universal interface for electrics, hydraulics, fuel, additives, water, air, oil; with measuring devices for recording all electrical measurands; with a control device 24 for generating and processing all control signals; with various media (e.g. Coriolis sensor from Danfoss); with sensors for time measurement, for image acquisition, and for force measurement; with a scanner for data matrix (batch and date); with traceability components (linking of part numbers with date, batch, and evaluation); and with components for calibrating the measuring technology. The interfaces 23 of the diagnostic devices 38 indicated in FIG. 5 are matched with all predefined interfaces 23 of the modules 11-22 to be tested.

[0063] Advantageously, the diagnostic device 38 comprises an ERP interface for data acquisition; for conversion in a formatted database; for assignment of measuring data to part number, batch, date, and order number; for data archiving in a database; for printout of test reports as required; for statistical evaluations; and generally for evaluation (good/bad).

[0064] A rework station includes a complete set of assembly tools, a workbench, media tanks, devices for evaluating an error, and devices for error elimination. After such an error elimination, a return to the measuring station takes place to carry out another check by means of the diagnostic device 38.

[0065] All modules 11-22 that have been checked and found to be in good condition are joined and bolted together step by step in the course of the final assembly. Similar to a terminal building block assembly box, all function modules 11-22 are placed on top of each other and connected to each other and/or to the vehicle frame 1. This joining process is preferably done from top to bottom. Alternatively, a joining process from bottom to top would also be possible. By predefining the module arrangement, the assembly sequence, and the assembly positions, the vehicle 2 can be assembled on a track 39 in a short time by means of a mobile crane.

[0066] After module assembly and module testing have taken place, the system functions are tested and verified. Here, in a manual or in an automated process, the main functions are activated and the reactions are measured. This makes it possible to test and verify simple I/O processes as well as complex system functions. The operational limits are defined and good/bad evaluations can be standardized and automated.

[0067] The common parts concept is explained with reference to FIG. 7. The basis for all modules 11-22 is the same vehicle frame 1. The vehicles 2 shown differ in structure due to differently selected add-on modules 12-22. For example, the topmost vehicle comprises a drive cab module 21, a social cab module 18, a workshop module 17 with platform, a technical room module 19, and another drive cab module 21. In the middle vehicle 2, the workshop module 17 is combined with a storage compartment. The lower vehicle 2 has a loading area module 20 instead of a social cab 18. A control software for actuating the modules 11-22 is set up in the control device 24. A software module 40 is assigned to each selectable function module 11-22. The software modules 40 are enabled in accordance with the function modules 11-22 set up on the respective vehicle 2.

[0068] FIG. 8 shows a fully assembled work vehicle 1 on a track 39, with a crane module 12, a drive cab/crane cab 21, a social/workshop module 17, 18, a lifting platform module 13, an overhead line and energy supply module 16, and a further drive cab 21 as overfloor modules. Further modules 22 (e.g. various work units) are mounted on the roof. A traction module (power pack) 14, a tank module 15 for fuel, a tank module 15 for hydraulic oil, and various other modules 22 (e.g. transformer module, cooling system module, brake resistor module, battery module with battery thermal management system) are arranged as underfloor modules.

[0069] Two alternative traction modules 14 are shown in FIGS. 9 and 10. The conceptual structure is divided into a fixed area, a modular area 35, and an expandable area 36. The fixed area houses, for example, an internal combustion engine 37, a coolant radiator 41, an intercooler 42, an exhaust system 43, and a urea solution tank.

[0070] Different components are arranged in the modular area so that the traction module 14 serves, for example, as a diesel-electric energy source, as a hydrostatic energy source, or as a hydrodynamic energy source. In the diesel-electric version shown in FIG. 9, the internal combustion engine 37 is coupled with a generator 44 and with hydraulic pumps 45. In the hydrostatic version shown in FIG. 10, the internal combustion engine 37 is coupled with a pump distributor gearbox 46. In the expandable area 36, an exhaust flap 47 is located, for example.

[0071] A supporting frame 48 with connecting bearings serves as predefined mechanical interfaces 23 for connecting the individual components. If necessary, the supporting frame 48 is mounted on the vehicle frame 1 by means of an auxiliary frame 25. The complete unit can be easily dismantled for servicing. The concept described can also be applied to other modules such as an accumulator module, a hydraulic module, a fuel tank module, a transformer module, or a cooling system module.