JP7516272B2 - Rail vehicle and manufacturing method for rail vehicle - Google Patents

Description

The present invention relates to a rail vehicle and a method for manufacturing a rail vehicle.

In general, railway vehicles that operate along an installed track require the underframe, which forms the floor of the vehicle, to have insulation performance that prevents atmospheric heat in summer when the outside temperature is high, and heat generated by equipment placed under the floor, from penetrating into the interior of the vehicle through the underframe.

Patent Document 1 proposes a floor structure for a linear motor vehicle that can provide the same fire resistance as conventional linear motor vehicles, without compressing the space under the floor for cables, piping, equipment, etc., in a linear motor vehicle with a small space under the floor. Patent Document 1 discloses a technology in which a plate-shaped expansion type insulation material is arranged under the floor in a floor structure for a linear motor vehicle in which the underside of the floor plate is supported by a beam structure that combines multiple beam members extending in the front-rear direction of the vehicle and multiple beam members extending in the vehicle width direction.

JP 2009-196531 A

Generally, railway vehicles that have heat resistance on the outside surface of the underframe that forms the floor of the railway vehicle tend to require a large number of manufacturing steps because they require the application of insulation materials that suppress the transfer of heat inside and outside the vehicle, as well as protective plates that restrain the insulation materials and protect them from flying objects (such as ballast laid on the track).

The present invention was made in consideration of the problems with the conventional technology, and aims to provide a rail vehicle having an underframe with enhanced thermal insulation while reducing manufacturing man-hours, and a method for manufacturing the rail vehicle.

In order to solve the above problems, one representative rail vehicle of the present invention is as follows:
A rail vehicle having a frame forming a floor surface,
the underframe comprises an interior side panel, an exterior side panel, and a connecting member connecting the interior side panel and the exterior side panel, and is formed of a hollow extruded shape extruded along a longitudinal direction of the railway vehicle;
the vehicle exterior side panel has a plurality of curtain rail structures including a vertical piece having one end in a height direction connected to the vehicle exterior side panel and a horizontal piece extending in one horizontal direction from the other end in the height direction of the vertical piece,
the heat insulating section configured on the vehicle exterior side of the underframe is composed of a heat insulating material provided on the vehicle exterior surface of the vehicle exterior side panel between the curtain rail structures, a heat insulating plate that holds the heat insulating material between the vehicle exterior side panel, an insulating part interposed between a horizontal piece of the curtain rail structure and the heat insulating plate, and a mechanical fastening part that fixes the heat insulating plate to the curtain rail structure ,
The insulation material in a free state has a thickness dimension that is greater than a dimension from one end to the other end in a height direction of the vertical piece,
The heat insulating material is compressed in the height direction by fastening the mechanical fastening portion that fixes the heat insulating plate to the curtain rail structure,
The heat insulating plate has a horizontal portion and a vertical portion erected at an end portion in a width direction of the horizontal portion, and has a plurality of protective plates having a cross section intersecting the longitudinal direction and having a substantially L-shaped cross section,
A distance between the vertical pieces of the protection plates whose horizontal portions face each other is set to be larger than a distance between the vertical pieces of the protection plates whose horizontal portions face in opposite directions,
The curtain rail structure is achieved by arranging the horizontal portion between the vertical pieces of the protective plates facing in opposite directions .

According to the present invention, it is possible to provide a railway vehicle having an underframe with enhanced thermal insulation while reducing the number of manufacturing steps, and a method for manufacturing a railway vehicle.
Problems, configurations and effects other than those described above will become apparent from the following description of the embodiments.

FIG. 1 is a side view of a railroad vehicle. FIG. 2 is a cross-sectional view intersecting the longitudinal direction of the railway vehicle (cross-sectional view taken along line AA in FIG. 1). FIG. 3 is a cross-sectional view (enlarged portion of portion B in FIG. 2) of an underframe which forms the floor of a railway vehicle and has high thermal insulation properties. FIG. 4 is an exploded view showing the elements that make up the thermally enhanced underframe. FIG. 5 is a flow chart showing the process of assembling the insulation section and attaching it to the underside of the underframe of a railcar. FIG. 6 is a cross-sectional view (cross-sectional view taken along CC in FIG. 7) of the heat insulating portion before it is attached to the underframe of the railway vehicle. FIG. 7 is a plan view of the insulation section prior to attachment to the underframe of a railway vehicle.

A rail vehicle is a general term for vehicles that run along an installed track, including railway cars, streetcars, new transit system vehicles, and monorail vehicles. Hereinafter, an embodiment of the present invention will be described with reference to the drawings, using a railway car as a representative example of a rail vehicle.

Below, an embodiment of the present invention will be described with reference to the drawings. First, each direction will be defined. The longitudinal direction of the railway vehicle (or the rail direction) is the x-direction, the width direction of the railway vehicle (or the sleeper direction) is the y-direction, and the height direction of the railway vehicle is the z-direction. Below, these directions may simply be referred to as the x-direction, y-direction, and z-direction.

Figure 1 is a side view of a railway vehicle, and Figure 2 is a cross-sectional view intersecting the longitudinal direction of the railway vehicle. The railway vehicle 1 is composed of a pair of bogies 7 that move along a track 9, and a vehicle structure 3 supported by the bogies 7. The vehicle structure 3 is a hexahedron consisting of an underframe 10 forming the floor surface, a pair of side structures 20 erected in the x direction at both ends of the underframe 10, a pair of end structures erected in the y direction at both ends of the underframe 10 in the x direction, and a roof structure 40 placed on the upper ends of the side structures 20 and the end structure.

The side structure 20 includes side sliding doors 24 for passengers to board and disembark, windows 22, etc. An air conditioning unit 42 that adjusts the temperature and humidity inside the passenger compartment is mounted on the top surface of the roof structure 40. Seats 18 and other items are provided inside the train (on the top surface of the floor of the frame 10).

Figure 3 is a cross-sectional view (enlarged portion of part B in Figure 2) of the underframe that forms the floor of the railway vehicle and has high thermal insulation, and Figure 4 is an exploded view showing the elements that make up the underframe with enhanced thermal insulation. The underframe 10 is composed of a hollow extruded material extruded in the x direction, with an interior side panel 11, an exterior side panel 12, and a connecting rib (connecting member) 13 that connects the two panels.

A curtain rail structure 15 that holds the insulation section 50 (described later) on the underframe 10's underside is integrally formed by extrusion molding on the exterior side panel 12 at an interval (pitch) P in the y direction. As shown in FIG. 4, the curtain rail structure 15 has a C-shaped cross-section channel structure composed of a horizontal piece 15H, a vertical piece 15V, and the exterior side panel 12.

The heat insulating section 50 is composed of a flat heat insulating plate 57, a protective plate 58 provided on the heat insulating plate 57 along the x direction, a heat insulating material 55 provided in a wide area (a section corresponding to the pitch P) defined by the protective plates 58 at a first interval, and an insulating section 56 provided in a narrow area defined by the protective plates 58 at a second interval narrower than the first interval. The protective plate 58 is composed of a horizontal portion 58L and a vertical portion 58V erected at one end of the horizontal portion 58L in the y direction, and the cross-sectional shape of the protective plate 58 intersecting the x direction is approximately L-shaped. The pair of protective plates 58 provided at the first interval are arranged with the horizontal portions 58L facing each other, and the pair of protective plates 58 provided at the second interval are arranged so that the horizontal portions 58L face in opposite directions.

The insulation part 50 is fastened to the curtain rail structure 15 of the outer side panel 12 on the underside of the underframe 10 by the mechanical fastening part 90. Here, the threaded part of the bolt, whose head is held in the C-shaped cross-section channel structure, protruding downward through the opposing edges of the horizontal piece 15H is passed through a hole in the insulation plate 57 and then screwed into a nut, thereby fastening the insulation plate 57.

If the insulating plate 57 constituting the insulating part 50 were to come into direct contact with the curtain rail structure 15, the heat transferred from the insulating plate 57 to the curtain rail structure 15 would move by conduction from the curtain rail structure 15 through the exterior side panel 12 and the connecting rib 13 to the interior side panel 11, and could enter the interior of the railway vehicle 1. For this reason, in this embodiment, an insulating part 56 is interposed between the contact surface between the horizontal piece 15H of the curtain rail structure 15 and the insulating plate 57 to suppress the transfer of heat from the insulating plate 57 to the curtain rail structure 15.

Figure 5 is a flow chart showing the process of assembling the insulation section and attaching it to the underside of the underframe of the railway vehicle. Figure 6 is a cross-sectional view (cross-sectional view C-C in Figure 7) of the insulation section before it is attached to the underframe of the railway vehicle. Figure 7 is a plan view of the insulation section before it is attached to the underframe of the railway vehicle. The manufacturing method of the railway vehicle will be explained with reference to the flow chart in Figure 5.

The steps in the flowchart in FIG. 5 will be explained with reference to FIG. 6 and FIG. 7. The "S" in the flowchart from S10 to S100 indicates a step.

In S10, the work of assembling the insulation section and attaching it to the underside of the frame of the railway vehicle begins.
In S20, a flat heat insulating plate 57 is prepared. A high-strength stainless steel plate is provided as the heat insulating plate 57 so as to withstand the impact of ballast laid on the track. For vehicles that run on a slab track or the like where there is no risk of ballast scattering, it is not necessary to use a stainless steel plate.

In S30, the horizontal portions 58L of the protective plates 58 are fixed to the flat insulating plate 57 so that the y-direction dimension between the vertical portions 58V of the pair of protective plates 58 facing each other is M2. The dimension M2 is set to be slightly smaller than the y-direction dimension L2 between the vertical pieces 15V of one curtain rail structure 15 and the vertical pieces 15V of the other curtain rail structure 15 adjacent to each other across the insulating material 55. Here, the y-direction dimension of the vertical portions 58V of the pair of adjacent protective plates 58 whose horizontal portions 58L face in opposite directions is M1, and the y-direction dimension of the vertical portions 58V of the pair of protective plates 58 whose horizontal portions 58L face each other is M2 (>M1).

In S40, an insulating section 56 made of a material with low thermal conductivity is provided between the vertical sections 58V of a pair of protective plates 58 adjacent to each other with their horizontal sections 58L facing in opposite directions.

As shown in FIG. 7, the insulating portions 56 have a rectangular plate shape with long sides along the x direction, and are arranged on the surface of the heat insulating plate 57 facing the underframe 10. Specifically, the insulating portions 56 are arranged discretely in the x direction with their longitudinal direction aligned with the x direction, and avoid the holes 57a through which the mechanical fastening portions 90 that fix the insulating portions 56 to the underframe 10 penetrate. The insulating portions 56 are also arranged discretely in the y direction, with the horizontal portions 58L being arranged between the vertical portions 58V of a pair of adjacent protective plates 58 facing in opposite directions.

In S50, a flat insulating material 55 is prepared and fixed between the vertical portions 58V of a pair of protective plates 58 whose horizontal portions 58L are fixed to the insulating plate 57. The y-direction dimension of the insulating material 55 is set to be slightly smaller than the y-direction dimension M2 of the vertical portions 58V of the pair of protective plates 58 whose horizontal portions 58L are opposed to each other. The thickness dimension t2 of the insulating material 55 in a free state (a state in which no external force is applied) is set to be larger than the height dimension t1 of the vertical portions 58V of the protective plates 58. The insulating material 55 is fixed to the surface of the insulating plate 57 facing the underframe 10.

In S60, the head of the mechanical fastening part (bolt) 90 is set (installed) in the curtain rail structure 15, which is extruded integrally with the outer side panel 12 of the underframe 10. The head of the mechanical fastening part 90 is held within the curtain rail structure 15, and its threaded part protrudes from between the opposing edges of the horizontal piece 15H due to gravity. When the polygonal head of the bolt hits the inner wall within the C-section channel structure and is rotated and fixed, it can be fastened by tightening only on one side, which provides excellent workability.

In S70, the screw portion of the machine fastening portion 90 is passed through the hole 57a of the insulation plate 57 to position the insulation plate 57 on the underside of the frame 10.

In S80, a nut is screwed onto the threaded portion of the mechanical fastening portion 90 and then tightened. In the process of tightening the mechanical fastening portion 90, the vertical portion 58V of the protective plate 58 is guided by the vertical piece 15V of the curtain rail structure 15, preventing the insulating plate 57 from tilting. The height dimension t1 of the vertical portion 58V of the protective plate 58 is set slightly smaller than the height dimension t3 of the curtain rail structure 15 that is integrally molded with the exterior side panel 12 of the frame 10.

At the same time, the insulating material 55 is compressed in the z direction to increase its density (reduce the porosity). In general, insulating materials with high density have better insulating properties than insulating materials with low density, so the compressed insulating section 50 has a higher thermal resistance and higher insulating performance.

When the insulation material 55 is compressed in the z direction, both ends in the y direction protrude, but because these ends are restrained by the vertical portion 58V of the protective plate 58, they are prevented from protruding toward the curtain rail structure 15. Therefore, when the mechanical fastening portion 90 is tightened, the insulation material 55 is prevented from being pinched between the surface of the horizontal piece 15H of the curtain rail structure 15 on the insulation section 50 side and the insulation plate 57, thereby ensuring the appropriate axial force of the mechanical fastening portion 90 for a long period of time.

In S90, the mechanical fastening portion 90 is tightened with an appropriate tightening torque to fix the heat insulating plate 57 to the underside of the underframe 10. At this time, the tip of the vertical portion 58V of the protective plate 58 abuts against the vehicle exterior side panel 12, preventing the heat insulating plate 57 from approaching the vehicle exterior side panel 12 any further, thereby suppressing excessive compression of the heat insulating material 55. Note that, since the area of the abutting surface between the vertical portion 58V and the vehicle exterior side panel 12 is relatively small, the amount of heat passing through the abutting surface is small.
In S100, the work of fixing the insulation section 50 to the underframe 10 is completed.

In a railway vehicle with the above configuration, the insulation section 50 containing the insulation material is disposed on the underside of the underframe 10, so that the exhaust heat from the underfloor equipment provided below the underframe 10 and the main motor that drives the bogie 7 can be prevented from being transmitted through the underframe 10 and entering the interior of the railway vehicle 1.

Furthermore, when the insulation section 50 is attached to the underside of the underframe 10, the insulation material 55 constituting the insulation section 50 is sandwiched and compressed between the outer side panel 12 of the underframe 10 and the insulation plate 57, so that insulation material of a larger thickness (with higher insulation performance) can be used without compressing the insulation material 55 in advance by outworking.

Furthermore, due to the structure in which the vertical portion 58V of the protective plate 58 fixed to the insulation plate 57 is guided to the vertical piece 15V of the curtain rail structure 15, it is possible to prevent the insulation material 55 protruding in the y direction from being pinched between the insulating part 56 provided on the protective plate 58 and the horizontal piece 15H of the curtain rail structure 15 of the underframe 10 during the process of compressing the insulation material 55 in the z direction. Therefore, when attaching the insulation part 50 to the underframe 10's underside, the axial force of the tightened mechanical fastening part 90 can be prevented from decreasing due to deterioration of the pinched insulation material 55 over time, thereby improving reliability.

Furthermore, according to the underfloor structure for railway vehicles of the present invention, the fiber-based insulation is compressed and attached, which reduces the void ratio of the fiber-based insulation, thereby improving insulation properties and effectively suppressing the temperature rise of the underframe.

Furthermore, since the insulation section 50 manufactured by outworking can be fixed below the underframe 10, it can be prepared in a process separate from the process for manufacturing the railway car 1, thereby reducing the overall manufacturing man-hours for the railway car 1.

1... railway vehicle, 3... vehicle body structure,
7...cart, 9...track,
10...frame, 11...interior side panel,
12... Vehicle exterior side panel; 13... Connection rib;
15... curtain rail structure, 18... seat,
50...insulating portion, 55...insulating material,
56...insulating part, 57...insulating plate,
57a...hole, 58...protective plate,
58L...Horizontal part, 58V...Vertical part,
20... side structure, 22... window,
24... side sliding door, 40... roof structure,
42...Air conditioner, 90...Mechanical fastening part,
t1: height of the guide plate 58; t2: thickness of the heat insulating material 55;
t3: height dimension of the curtain rail structure 15, x: longitudinal (rail) direction,
y: width (sleeper) direction, z: height direction

Claims (4)

A rail vehicle having a frame forming a floor surface,
the underframe comprises an interior side panel, an exterior side panel, and a connecting member connecting the interior side panel and the exterior side panel, and is formed of a hollow extruded shape extruded along a longitudinal direction of the railway vehicle;
the vehicle exterior side panel has a plurality of curtain rail structures including a vertical piece having one end in a height direction connected to the vehicle exterior side panel and a horizontal piece extending in one horizontal direction from the other end in the height direction of the vertical piece,
the heat insulating section configured on the vehicle exterior side of the underframe is composed of a heat insulating material provided on the vehicle exterior surface of the vehicle exterior side panel between the curtain rail structures, a heat insulating plate that holds the heat insulating material between the vehicle exterior side panel, an insulating part interposed between a horizontal piece of the curtain rail structure and the heat insulating plate, and a mechanical fastening part that fixes the heat insulating plate to the curtain rail structure ,
The insulation material in a free state has a thickness dimension that is greater than a dimension from one end to the other end in a height direction of the vertical piece,
The heat insulating material is compressed in the height direction by fastening the mechanical fastening portion that fixes the heat insulating plate to the curtain rail structure,
The heat insulating plate has a horizontal portion and a vertical portion erected at an end portion in a width direction of the horizontal portion, and has a plurality of protective plates having a cross section intersecting the longitudinal direction and having a substantially L-shaped cross section,
A distance between the vertical pieces of the protection plates whose horizontal portions face each other is set to be larger than a distance between the vertical pieces of the protection plates whose horizontal portions face in opposite directions,
The curtain rail structure of the railway vehicle is characterized in that the horizontal portion is arranged between the vertical pieces of the protective plates facing in opposite directions. The railway vehicle according to claim 1 ,
A railway vehicle, characterized in that a tip of the vertical portion of the protective plate abuts against the exterior side panel of the vehicle. 2. The method for manufacturing a railway vehicle according to claim 1 ,
The heat insulating material is disposed on the vehicle exterior side panel between the curtain rail structures,
The insulating portion is disposed on the horizontal piece of the curtain rail structure,
and fixing the insulation plate to the curtain rail structure while compressing the insulation material using the mechanical fastening portion. The method for manufacturing a railway vehicle according to claim 3 ,
A protective plate having a horizontal portion and a vertical portion erected at an end portion in the width direction of the horizontal portion and having a cross section intersecting the longitudinal direction in a substantially L-shaped shape is fixed to the insulating plate,
The heat insulating material is disposed between the vertical portions of the protective plates facing each other at the horizontal portions,
The insulating portion is disposed between the vertical portions of the protective plate with the horizontal portions facing in opposite directions,
A method for manufacturing a rail vehicle, comprising: fixing the insulating plate to the curtain rail structure while compressing the insulating material using the mechanical fastening portion so that the vertical portion of the protective plate, with the horizontal portion facing in the opposite direction, is guided into the curtain rail structure.

Images