RAIL CAR INDUSTRY

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RAIL CAR INDUSTRY

Air cushions enable the flexible factory

Air cushion technology allows new factory layouts to be realised and modern manufacturing concepts implemented in the rail car industry. This allows slow, rigid and expensive transport systems such as gantry cranes, fixed rail systems, traversers and assembly pits to be largely dispensed with.

Air cushion technology transforms dark, solidly built factory buildings dating from the last century into modern, clean and transparent industrial complexes.

Semi-automated transport of the superstructures is provided by tape-guided robot vehicles comprising 2, 3 or more transporters that communicate wirelessly with each other. Only one operator is required to control this system.

Air cushion-guided elevating platforms, work platforms and handling equipment are also used for assembly work.

 

OTHER BENefits:

  • High flexibility and simple adaptation to new products and production processes
  • Investment costs are reduced, productivity boosted and cycle times shortened
  • Vehicles of different lengths can be transported to the assembly stations: there are no fixed assembly stations, as these can be located anywhere and can be reached by the air cushions at any time 
  • Use of standardised support stands for all vehicles capable of being transported on air cushions
  • Uniform, flexible air cushion-capable assembly platforms with several levels that surround the vehicles
  • Safe, non-hazardous way of transporting the vehicles
  • Transport system easy to be operate by one employee floating load enables exact positioning accuracy
  • Floating load enables exact positioning accuracy
  • Assembly and measuring equipment led on air cushions (underfloor assembly, doors, corner load weighing unit)
  • Air cushion-borne bogie/motor bogie transport equipment for high-bay warehouses
Superstructures transported flexibly by means of air cushion robot vehicles
The robot vehicles are guided by tape and work in DUO, TRIO or QUATTRO mode
Transporting a double deck coach. The loads are usually between 50 t and 70 t.
The coach bodies are put on special supports which are picked up by the air cushion transporter.
Normally, a coach body is carried by two transporters. When transporting flexible tram chassis, up to four transporters are used.
Optical (or magnetic) guiding tapes make it easier to manoeuvre between tight assembly stands.
The assembly stands can be positioned flexibly and have multiple levels on which can be worked at the same time.
Transporters with hybrid running gears are equiped with driven rail wheels. These allow them to drive over pits as well.
Can be used in surface finishing stations (sandblasting, washing, painting)
The air cushion transports are equipped with rail wheels and explosion protection
Entry into the paint cabin.
In the paint cabin the transport system moves on its rail wheels.
Deployment in the repair shop for trams.
This is where the tramcars are washed regularly or repainted.
Entry into the blasting cabin.
Storage, transport and assembly of wheelsets and bogies
An air cushion allows an ICE bogie to be changed in just 15 minutes
This special elevating platform for putting bogies into storage was equipped with DELU air cushion running gears.
Transporting bogies to the assembly point.
The bogies are pulled onto the air cushion transporter by means of a cable winch.
Changing the bogie of a high-speed ICE train.
Configured with air cushions, the bogie changers can glide precisely in all directions.
DThis manually controlled roll transporter can pick the rail wheels straight off the ground.
Roof and exterior work on mobile work platforms
Autonomous, work platforms can run on air cushions for flexible use
Autonomous, elevating work platforms moving on air cushions can be used where flexibility is required, e.g. work on windows and doors.
These work platforms are equipped with air tanks that allow them to work independently of the compressed air supply for up to an hour or more.
The width of the work platform can also be infinitely adjusted to the edges of the coach body by up to 350 mm.
Work on the front of the coach body.
An integrated auxiliary drive allows the platforms to be moved rapidly and positioned precisely by just a single person.
Transport and underfloor assembly of heavy components with mobile scissor lifts
Shorter assembly times thanks to high mobility and ease of handling
Elevating platforms on air cushions can be used both in the preassembly of heavy switch cabinets and in the underfloor assembly of mechanical and electrical components.
The mobility provided by air cushions and the ease of operation mean that underfloor work can be carried out by just one or two people.
The elevating platforms can be equipped with a synchronous lifting device on request.
Preassembly of electrical components.
Air cushion elevating platform in narrow form.
Mobile measuring equipment
Mobile corner load weighing units save on expensive superstructure transport times
This air cushion-supported measuring unit is used to check the stress-free position and reference position of the coach body and to determine the corner forces in four-point supports.
It comprises a master unit configured with force and position transducer, computer, monitor and printer, a wireless controller for the elevating system and wireless data communication for the measuring data.
The mobile corner load weighing unit allows the fully assembled rail carriage to be measured at any location in the assembly hall, making a transporter generally superfluous.
The use of a wireless remote control for the elevating systems and wireless data communication for the measuring data eliminates the need to lay control and measuring cables.
The DELU corner load weighing unit allows the benefits of flexible assembly to be exploited to the full and was used for the first time in the Pankow plant of ADtranz.
Assembly of doors and windows
Extremely simple assembly and handling
Window and door assembly units moving on air cushions.
They make handling simple, easy and quicker.
The door is held by a vacuum gripper and raised by a hydraulic cylinder. Air cushions allow it to be positioned precisely.
Special applications
Air cushion technology opens up a wide range of different applications
Two-track air cushion rail points for trams installed outdoors.
This traverser was expanded with an air cushion transporter to enable it to pick up and move even long trams.