Patent Application
20240367697
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. In addition, the invention relates to a method for assembling the work vehicle.
A generic work vehicle is known from AT 520 066 A1. A work platform and a crane with a personnel basket are arranged as mounted structures with assigned functions. During a work operation, the vehicle is supplied with electrical energy from a plurality of energy storage modules (battery packs).
AT 16702 U2 discloses a similar work vehicle in which a supply is also provided by means of energy storage modules. Length wise, mounted structures of the work vehicle are divided into a plurality of sections. One of these sections is a walk-in operating room that houses the energy storage modules. By varying the module arrangements, different switch cabinet heights and thus different room heights can be achieved. This allows a recess in the vehicle roof into which a work platform can be lowered while being taken out of service.
The object of the invention is to improve a work vehicle of the kind mentioned above in such a way that different mounted structures can be arranged on the vehicle in an efficient manner. A further object of the invention is to indicate a corresponding method for assembling the work vehicle.
According to the invention, these objects are achieved by the features of independent claims 1 and 13. Dependent claims indicate advantageous embodiments of the invention.
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 function modules are characterized by the inherent function, an input, and an output, by system boundaries, and the predefined interfaces as well as by interactions with other function modules, and with an overall machine function. Such self-supporting function modules are completely pre-assembled and thoroughly checked before installation in the work vehicle takes place. If necessary, module surfaces are also painted in advance so that the vehicle is already ready for use after module assembly. The predefined interfaces enable the interconnection of different function modules without further adaptations. The checks carried out in advance are done by means of a diagnostic device with the same predefined interfaces. In particular, the diagnostic device comprises universal measuring and testing devices and joining elements for mechanical fastening of the respective self-supporting function module as well as a control device for actuating various function modules. The module diagnosis and the system check before assembly optimize the time required for vehicle commissioning. 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.
The vehicle according to the invention exhibits a high level of operational safety due to the comprehensive module checks and due to any corrections. Early error detection during module checking and system verification after module assembly minimizes error costs. In addition, the operational limits of the individual function modules are predefined and can be tested. The interactions of the module functions are also known in advance. The smaller number of parts variants compared to known vehicle concepts results in a further increase in operational safety.
In the case of a modified combination of function modules, a type test and declaration of conformity carried out once in advance leads to a simplified subsequent approval. The use of the declaration of conformity instead of a plurality of individual type tests and the faster assembly reduce the manufacturing lead time. New module combinations make it easy to expand the vehicle's operational functions and operational range through new functions.
In particular, the elimination of a conventional mechanical assembly and the avoidance of welding in the final assembly contribute to the prevention of errors. Overall, the modular design ensures a simplification of maintenance work and an easy retrofitting of technical adaptations. At the end of the life cycle, a simple scrapping and recycling of the raw materials is feasible.
Advantageously, the predefined interfaces are designed as mechanical, and electrical, and/or hydraulic, and/or pneumatic interfaces. The interfaces of the individual function modules are connected directly to each other or by means of modular lines. These lines are positioned in defined channels and line guides and fixed in position at the interfaces, which are designed, for example, as plugs, flanges, or quick-release fasteners. In particular, the interfaces are used for fastening, energy supply, communication, and diagnosis of the individual function modules. A corresponding diagnostic device usefully comprises a universal interface for electrics, hydraulics, compressed air, fuel, water, oil, and various auxiliary materials (e.g. urea solution for internal combustion engine).
In a further improvement, the predefined interfaces comprise joining elements which enable an adjustment of the respective function module, in particular, in two directions orthogonal to each other. This ensures a precise positioning of the modules during final assembly. The mechanical interfaces or joining elements are an exact fit and can be fixed by means of threaded connections. This eliminates the need for welding during final assembly. The joining connections have compensations for volume and length dilation due to thermal expansion, etc. During final assembly, the individual function modules are joined together step by step on the vehicle frame, which serves as a platform, with the defined mechanical interfaces being used for fastening. For example, fastening is done via perforated grids with threaded connections and elastic suspensions. Unique joining positions are assigned, thus preventing collisions of components.
In a further development, the predefined interfaces comprise joining elements that have a unique geometric fit to each other. This means that unique connections are predefined, which prevents interface errors. Preferably, principles of Poka Yoke are applied, for example, a shape coding for specifying unambiguous orientation positions.
A vehicle frame with two lateral longitudinal carriers, the upper edges of which span a vehicle floor, is advantageous, with at least one function module being arranged as an underfloor module below the vehicle floor. Thus, the vehicle floor is to be regarded as a separating level between a space for an overfloor assembly of function modules and a space for an underfloor assembly of function modules. The respective assembly space can be varied in size and shape by the arrangement and dimensioning of the longitudinal carriers. The arrangement of transverse carriers that are rigidly connected to the longitudinal carriers also influences the respective assembly space.
Advantageously, the respective longitudinal carrier comprises a longitudinal-carrier upper flange and a longitudinal-carrier lower flange, which are connected to each other by a plurality of connecting elements arranged at equal distances from one other. The design of the lower flange also determines the space for the underfloor assembly. Each lower flange is connected to the assigned upper flange in a standardized manner via the connecting elements (struts). This design reinforces the bending, tension-compression, and torsional rigidity of the frame without restricting the assembly space for the function modules.
In a useful further development of the invention, an underfloor module is designed as a traction module, with the traction module comprising an internal combustion engine coupled to a generator and/or a pump distributor gearbox. Such a traction module for moving the vehicle also supplies the other function modules with energy.
An arrangement in which at least one function module is designed to be shiftable on guides in relation to the vehicle frame is advantageous. This allows the position of the vehicle's centre of gravity to be shifted in order to optimize the weight distribution on the rail running gears. For this weight trimming, the corresponding function module can be shifted in steps or steplessly in the longitudinal direction and in the transverse direction.
Preferably, a shiftable function module such as a tank, power pack, etc. is fastened to an auxiliary frame. The assembly position is varied in the transverse direction by shifting the respective function module sideways on the auxiliary frame.
In a further improvement of the invention, the vehicle frame is divided into three sections in the longitudinal direction, with the drive cab being arranged on one end section, with a crane module or a further cab being arranged on the other end section, and with further function modules being set up on the middle section. With this longitudinal design kit concept, the assembly space for the assembly of the function modules is invariable in width and variable in length and height. In particular, the middle section can be varied in the longitudinal direction to enable the arrangement of different function modules.
For an advantageous combination of selected function modules, the assembly space, 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. Preferably, four segments are arranged in the vertical direction (e.g. bogie, cab, roof-mounted structures, and underfloor arrangement), ten segments in the longitudinal direction (e.g. buffers and draw hooks, cab, crane, loading area, etc.), and three segments in the transverse direction (e.g. driver seat, pilot seat, etc.).
In a further improvement, a modular control software is set up in a control device, with different function modules being assigned their own software modules and with the software modules being able to be enabled separately. The modular concept of the control software conforms to the function modules that can be selected from a predefined module catalogue, with the control software being able to be adapted to the respective configuration of the machine functions.
In the method according to the invention for assembling the described work vehicle, the vehicle frame is manufactured with a dimensioning adapted to selected function modules, with each function module being initially pre-assembled as a self-supporting unit and with the pre-assembled function modules being bolted to the vehicle frame and/or to each other. The vehicle frame serves as a platform that can be varied and scaled in width, length, and height according to defined standards.
The reduced number of component variants compared to conventional vehicle concepts results in further advantages. Manufacturing costs are reduced and logistics are simplified through minimum inventory management of function modules and module components. A high level of detail enables an easy understanding and a clear assignment of the assembly units and individual parts. The assembly concept offers a high number of repetitions, with common parts with few standard part variants being used. In addition, CAD assembly tools (e.g. 3D representations of the individual components in the assembled state, or virtual reality, or augmented reality as an assembly aid) enable a simplified standardized assembly.
In a further development of the method, the respective pre-assembled function module is put into operation before installation by means of a diagnostic device. In this way, a geometric and functional check of each function module is carried out in order to eliminate possible errors or weak points before installation. Specifically, module diagnosis is a procedure by means of a testing device for quantitative measurement and assessment of the individual function modules and for qualitative evaluation of the functional systems for final assembly. The quality assurance and consistent validation achieved in this way, according to a rapid test procedure for quantitative performance evaluation of the function units, serves for evaluation and documentation for traceability and obsolescence management.
In another improvement, a modular control software set up in a control device is adapted to the installed function modules. For each selected and installed function module, the corresponding part of the control software is activated and released. This facilitates a structured programming of the machine control system. In addition, adaptations to changed requirements and legal prerequisites are feasible in a simple manner by exchanging individual function modules and control building blocks.
In the following, the invention is explained by way of example with reference to the accompanying figures. The following figures show in schematic illustrations:
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.
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.
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.
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.
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.
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.
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
The assembly of the work vehicle 2 is explained with reference to
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.).
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.
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.
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.
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.
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:
A universal diagnostic device 38, shown schematically in
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).
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.
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.
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.
The common parts concept is explained with reference to
Two alternative traction modules 14 are shown in
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
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.
| Number | Date | Country | Kind |
|---|---|---|---|
| A50683/2021 | Aug 2021 | AT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/072525 | 8/11/2022 | WO |
