SIDE-WALL FRAME ASSEMBLIES FOR RAILWAY CARRIAGES

Abstract: In constructing a railway carriage side-wall frame assembly having a plurality of straight or curved upright structural elements (14, 21) interconnected with one or more horizontal structural elements (12) forming a framework, a deformed portion (25) is provided on one of the structural elements at each interconnection for locating the element to be interconnected therewith. The deformed portion (25) is formed by a deforming tool the relative positions of the tool and the structural element being adjustable whereby the position of the deformed portion along the structural member can be varied. Where two or more deformed portions are provided on the same element, the spacing between the deformed portions can be varied. Thus, variations in framework configurations having different interconnecting points can readily be achieved using common components and allowing for example different window sizes and positions to be accomodated as required.

Description: Side-Wall Frame Assemblies for Railway Carriages This invention relates to side-wall frame assembl¬ ies for railway carriages, and especially their method of 5 construction. The invention is applicable particularly to railway passenger coaches having windows. Side-wall frame assemblies for windowed coaches are usually constructed in the form of a lattice-like framework comprising interconnected upright structural elements, i.e. * * • " pillars, and horizontal structural elements, i.e. rails, the pillars and rails being so arranged as to define openings of preselected size and at predetermined locations along the length of the side-wall for receiving correspondingly sized window frames therein. 5 There exists a need to be able to adapt the con¬ struction of side-wall assemblies so as to accommodate alternative sized windows at possibly different locations to suit individual customer requirements and it is an object of the present invention to provide a method for use in the 0 construction of railway carriage side-wall assemblies which enables such adaptation to be accomplished easily and conveniently. According to one aspect of the present invention, a method of constructing a railway carriage side-wall frame assembly of a kind having a plurality of spaced elongate upright structural elements interconnected with. one or more elongate horizontal structural elements to form a structural framework, comprises the steps of forming the structural elements of required length and cross-sectional shape, thereafter providing for each interconnection between upright and horizontal structural elements a deformed portion on one of the elements for locating the other 5 structural element at the interconnection, by means of a tool having a deforming tool part, the relative positions of the tool part and said one structural element being .adjustable to enable variation of the position of the deformed portion along the length of said one structural - element, and thereafter interconnecting the elements together at said deformed portion with said other element located by said deformed portion. The ability to be able readily to adjust the position of the deformed portion as desired enables changes 5 to the configuration of the interconnected structural elements to be easily, and economically, effected. Importantly, considerable flexibility in construction is offered whereby a variety of configurations of frameworks having differently positioned interconnection points to accommodate alternative sizes, and locations, of windows can conveniently be produced using common initial components and the same tools. The said one structural element may be provided with two or more said deformed portions for interconnection with a corresponding number of . other structural elements. In this case said one structural element may be movable relatively to said tool part in order to position it to form each of said deformed portions. Alternatively, the tool may have a number of tool parts corresponding to the number of deformed portions and each capable of providing a said deformed portion the spacing of said tool parts being adjustable to vary the spacing between said deformed portions. The one or more deformed portions are preferably provided on the plurality of upright structural elements of the framework, although, alternatively, they may be provided on the one or more horizontal structural elements. Each deformation is advantageously in the form of an indentation complementary in shape to the shape of structural element to be received thereon and such that the outermost surfaces of the interconnected structural elements are flush, thereby facilitating the mounting of a side-wall skin thereon. Side-wall frame assemblies for railway carriages and their method of construction in accordance with the invention will now be described, by way of example, with reference to the accompanying drawings in which:- Figure 1 is a perspective, fragmentary, view of a section of a partly assembled railway carriage illustrating the general cons¬ truction of its side-wall frame, under- frame, and roof assemblies; Figure 2 is a fragmentary view, partly in section of a part of the carriage side-wall frame assembly of Figure 1 showing construction¬ al details; Figure 3 is a side view of an alternative form of upright structural element for use in constructing the framework; Figure 4 shows in part how the arrangement of Figure 2 is modified when the alternative form of upright structural element of Figure 3 is used. Figure 5 shows schematically one form of pressing tool for use in the invention; and Figure 6 shows another form of pressing tool. Referring to Figure 1, sections of two side-wall frame assemblies are shown joined with underfra e and roof sub-assemblies in the construction of a railway carriage, or more precisely a passenger coach. Each side-wall frame assembly comprises a right-angled lattice-like framework of interconnected upright structural elements, i.e. pillars, and one or more horizontal structural elements, i.e. rails, the framework presenting an outer surface on which a metal sheet side-wall skin is subsequently mounted by welding. The pillars and rails are arranged with respect to each other so as to leave openings of predetermined size at required positions along the length of the carriage, usually at regular intervals, for receiving window frames. In the particular variant of carriage illustrated in Figure 1, the framework of each side-wall frame 10 has two horizontal rails 11 and 12, extending longitudinally of the carriage which are interconnected at preselected locations along their lengths with pillars 14, here arranged in pairs, extending the height of the side-wall. The pillars 14 are connected at their respective lower and upper ends with a sole bar 15 and a parallel header beam 16 runn¬ ing the length of the carriage. Window openings, referenc- ed ^ at 17, are provided in the framework with their lower edges being defined by the upper rail 12 and their sides by facing pillars 14 of each adjacent pair of pillars. The upper window opening line is in this particular case defined by the header beam 16 * . The side-wall framework configuration shown in Figure 1 is by way of example only 'and it should be under¬ stood that different configurations of rails and pillars may be used in the construction of side-wall frame assemblies according to strength and size requirements. In alter- native variants there may be, for example, only one longi¬ tudinal rail used in the assembly, this being preferably situated at or below the lower window opening line, whilst there may also be an additional rail extending along the upper part of the framework, towards the header beam 16,. which serves to define the upper window opening line.. Furthermore, there could be only one or more than two pillars 14 situated between each adjacent window opening. As is also shown in Figure 1, the framework includ¬ es additionally a number of stump pillars 20, each compris- ing for convenience a ' cut-down pillar 14, and a number of smaller-section stump pillars. 21, one of each of which extends from the sole 'bar 15 up to the rail 12 beneath each window opening. Completing the framework are spacer members 22 connecting respective pillars 14 in each pair of pillars at the ' side of the openings 17. The rails and pillars of the framework are formed as channel sections. More particularly, the rails are of cha j inel section as shown in Figure 2, that is having a flat base, diverging sides and parallel, outwardly-directed side flanges. The pillars 14, and also the stump pillars 20, are, as can also be seen in Figure 2, of right-angled ϋ-shape channel section with parallel outwardly- directed side flanges, this kind of section being referred to as "top-hat" section. The stump pillars 21, one of which is shown in Figure 2, are of simpler "Z-shape" channel section. The construction of a side-wall frame assembly will now be described. Firstly, pillars 14 .are formed by pressing in a press, steel strip material into the required cross-sectional ' shape and length. Similarly the channel section rails 11 and 12 and the stump pillars 21 are formed by pressing steel strip material into desired lengths and cross-sectional shapes. Following pressing of the pillars, indentations such as that shown at 25 in-Figure 2, are provided on the pillars 14 at preselected locations therealong corresponding to the positions where the rails 11 and 12 are required to cross over the pillars 14, i.e. at each interconnection between rail and pillar, whose purpose is to engage with and locate the rails on the pillars 14 at- those cross-over points. The indentations 25, there being two on ea-ch of the pillars 14 of the particular carriage variant shown in Figure 1, are made on each pillar 14 simultaneously by means of the press tool shown in Figure 5 which has two separate pressing parts 36,38 for forming respective indentations. The pressing parts 36,38 are each individually movable with respect to the bed 34 on which the pillar 14 is held during pressing and are movable relatively to each other. The pillar 14 is held up against stop 35 to accurately position it in the press. Hence, the positions of the indentations along the length of the pillar 14 and the relative spacing therebetween can readily be altered by suitable adjustment of the pressing parts 36,38 of the press tool with respect to the pillar 14. Alternatively, the stop 35 may be adjustable and one of the pressing parts 36,38 fixed. The individual pressing parts of the tool are each designed to .deform the pillar 14 to define in the flanges and side walls of its channel section a recess of shape complementary to the profile of rails 11 and 12 and such that when a rail is received in the recess, the outermost flange surfaces of the rail and pillar are flush with- one another. As a result, and following completion of the joint by welding the parts together around the joint, the interconnection achieved between the rail and pillar is structurally very strong. Moreover, the rail and the pillar thereby also present flush surfaces into which a side-wall skin can be mounted. Having formed indentations 25 in the above manner, the pillars 14 are removed from the press tool and placed in a jig together with the rails 11 and 12, the spacer members 22, the stump pillars 20 these having been cut from so-formed pillars 14 and thus equipped with correctly positioned indentations, and the stump pillars 21. The latter also have had similar indentations formed thereon, preferably by using the same press tool. The frame assembly is then welded together at the crossing points of the frame members. In an alternative form of press tool, this tool being shown schematically in Figure 6, the pre-formed channel section pillar 14 is laid on a bed 34 of the press tool with one end against a locating stop 35, located on the bed so that the region of the pillar 14 to be deformed lies directly beneath a tool part 36 at a fixed position along the bed. The pillar 14 is held securely on and supported by the bed 34 and the tool part 36 moved downwardly to press the indentation ^25^ in the pillar. Following withdrawal of the tool part, the stop 35 is removed from its operative position and the pillar 14 moved across the bed until its end abuts a further locating stop 37 positioned such that the region of the pillar 14 where the second indentation is to be formed now lies directly beneath the tool part 36. The tool part 36 is then operated again to form the second indentation. The locating stops 35 and 37 are adjustable in position on the bed 34 so that the location of the indentations along the length of the pillar 14 and the relative spacing therebetween can be changed as required. Rather than using two stops 35 and 37, the stop 35 may simply be slid continuously along the bed 34 and clamped at positions defining the two required stop locations. It will be appreciated that in any of the forms of pressing tool, more than two indentations may be formed in each pillar 14 if required by providing an appropriate number either of adjustable locating stops on the bed or relatively movable pressing tool parts. Of course, where only one indentation is required either only one adjustable tool part . or one adjustable locating stop need be provided. The configuration in which the pillars and rails are interconnected and assembled together, as dictated by the respective positions of the indentations on the pillars, determines the size and location of the window openings 17 in the framework. The opportunity to vary the position of the indentations 25 along the length of the pillars 14 made possible by the use of the adjustable press tool described above enables different configurations of framework to be easily and conveniently produced. Thus, by moving the positions of the indentations 25 on the pillars 14 upwardly for example, the rails can be positioned higher so as to accommodate a window frame of less height. Conversely, by positioning the indentations further shown, a greater height of window frame can be accommodated. Also, by virtue of the nature of the indentations, the pillars can easily be moved as desired longitudinally along the rails thereby to accommodate different . widths of window frames. Hence considerable flexibility in the construction of framework 5 is achieved with the useful capability of changing readily the configuration of the framework to suit different requirements regarding window size and location. Moreover, the constructional method employed en- ables variants to be produced using, firstly, common initial components, i.e. rails 11 and 12 and pillars 14 prior to indentation, and, secondly, the same press tools, and is thus significantly more economical than methods used hereto¬ fore. Once assembled the side-wall frame is connected with the underframe and roof structure of the carriage by attaching the upper ends of the pillars 14 to the header beam 16 and the lower ends of the pillars, together with those of the stump pillars 20 and 21, to the sole bar 15 as shown in Figures 1 and 2, using any suitable bracketing. The side-wall is completed by the provision of window frames side wall skin, and internal fitments. In the kind of side-wall assembly described with reference to Figures 1 and 2, straight pillars 14, 20 and 21 are used. However, the pillars 14 and likewise the stump pillars 20 and 21, may be curved at their lower ends and used to construct a side-wall frame assembly of curved profile. As can be seen in Figure 3, the alternative form of pillar, referenced 14', is generally very similar except that it is rounded towards ' the lower end. The particular form of pillar shown in Figure 3 is intended to be used in the construction of a framework having just one rail below the window opening and, unlike the aforementioned arrange- ment, one rail above the window opening, and accordingly is provided with two rail-receiving indentations 25, above and below the window opening respectively. Also shown in Figure 3 is a further indentation 30 intermediate the indentations 25 - pressed into one side only of the channel section simultaneously with the indentation 25 for receiving an end of a spacer member 22. The pillar 14' is formed in an identical manner to pillar 14, that is by pressing strip steel into the required length and channel section, and thereafter the indentations 25 are provided at selected positions along its length using the adjustable press tool described. The curved end portion is then formed or formed prior to indentation by either rolling its end portion between two rollers of fixed diameters, or alternatively by pulling the end of the pillar around a single arcuate former, again of fixed diameter i.e. by stretch forming. By varying the extent of rolling along the pillar 14' or the amount by which the pillar end is pulled around the former, the degree of curving can be changed as desired to change correspondingly the carriage side wall profile. Of course, the location of the indentations can be easily adjusted in accordance with the degree of curving provided. Although both indentations 25 are shown in Figure 3 as being above the curved portion of the pillar, the lowe ' r indentation, or a further indentation could, if desired, be located in the curved portion. Figure 4 illustrates the manner in which the alternative form of pillar 14' is attached to the sole bar _ 15 using bracketing for comparison with the arrangement of Figure 2. Whilst in all the aforementioned methods of con¬ structing side-wall frame assemblies, the indentations 25 for ^ locating interconnections between the rails and pillars have been provided in the pillars 14, it is envisaged that indentations may instead be provided on the rails for receiving the pillars in similar fashion. In such a case, the rails may be provided on their outer side with indent- ations of shape corresponding to the pillar channel section using the adjustable press tool, with suitably modified press parts, so as to enable the position of the indentat¬ ions to be varied as desired as previously described. Assembly of the pillars and rails is then carried out as before except that the pillars are this time positioned outwardly of the rails and located in the indentations of the rails. It will be appreciated that in using such an arrangement similar flexibility in producing variations in framework configuration to accommodate alternative sizes and locations of windows can be achieved.

Claims: CLAIMS 1. A method of constructing a railway carriage side- wall frame assembly of a kind having a plurality of spaced elongate upright structural elements interconnected with one or more elongate horizontal structural elements to form a structural framework comprising the steps of forming the structural elements of required length and cross-sectional shape, thereafter providing for each interconnection between upright and horizontal structural elements a deformed portion on one of the elements for locating the other structural element at the interconnection, by means of a tool having a deforming.tool part, the relative positions of the tool part and said one structural element being adjustable to enable variation of the position of the deformed portion along the length of said one structural element, and thereafter interconnecting the elements together at said deformed portion with said other element located by said deformed portion. 2. A method according to Claim 1, wherein said one structural element is provided with two or more said deform¬ ed portions for interconnection with a corresponding number of said other structural elements. 3. A method according to Claim 2, wherein said one structural member is movable relatively to said tool part in order to position it to form each of said deformed portions. 4. A method according to Claim- 3, wherein the movement of said one structural member is limited by stop means. 5. A method according to Claim 2, wherein the tool has a . number of tool parts corresponding to the number of deformed portions, each tool part being capable of providing a said deformed portion and the spacing of said tool parts being adjustable to vary the spacing between said deformed portions. 6. A method according to any one of the preceding claims, wherein the one or more said deformed portions are provided on the plurality of upright structural elements of the framework. 7. A method according to any one of Claims 1 to 5, wherein the one or more said deformed portions are provided on the one or more horizontal structural elements. 8. A method according to any one of the preceding claims, wherein the deformation at the said deformed portion is in the form of an indentation complementary in shape to the cross-sectional shape of the structural element to be received thereon and such that the outermost surfaces of the interconnected structural elements are flush. 9- r method according to any one of the preceding claims, wherein . the interconnected structural elements are secured together at said deformed portion by welding. .

Inventors: TIPPING RAYMOND MICHAEL, TIPPING, RAYMOND, MICHAEL
Applicants: BRITISH RAILWAYS BOARD
Application year: 1985
Main classification: B61D17
IPC codes: B61D17