氣密工裝規(guī)范

1、Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 1 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-00Pressure Tightness Mock UpEngineering Description andOperation DescriptionOrder Nr. A9982氣密測(cè)試工裝的技術(shù)和操作規(guī)范氣密測(cè)試工裝的技術(shù)和操作規(guī)范Author:Franz HaiderIssue:00Date first

2、 issue:2007-05-18Pg No: 2 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-001DOCUMENT REVISION HISTORY文件修訂歷史.31.1CHANGE CONTROL更改控制.31.2CONFIDENTIALITY AND COPYRIGHT機(jī)密性和版權(quán) .32AIM OF PRESSURE TIGHTNESS MOCK UP 氣密測(cè)試工裝目的 .42.1GENERAL SPACE REQUESTS總的空間要求.42.2REQUESTS OF

3、 UIC 660: UIC 660 要求.42.3REQUESTS OF PROJECT RAILJET: RAILJET 項(xiàng)目要求 .52.3.1Type Test Requests型式試驗(yàn)要求型式試驗(yàn)要求.52.3.2Routine Requests 常規(guī)要求常規(guī)要求 .52.4REQUESTS OF PROJECT SSL: SSL 項(xiàng)目要求 .52.4.1Type Test Requests型式試驗(yàn)要求型式試驗(yàn)要求.52.4.2Routine Requests 常規(guī)要求常規(guī)要求 .63MECHANICAL DESIGN機(jī)械設(shè)計(jì).73.1FIXED MOCK UP HALF: 固定的半工

4、裝 .73.2MOVEABLE MOCK UP HALF: 活動(dòng)的半工裝 .103.3CONNECTION BETWEEN TWO MOCK UP HALVES: 兩個(gè)半工裝之間的連接.103.4DESK DESIGN臺(tái)面設(shè)計(jì) .114PNEUMATICAL DESIGN氣動(dòng)設(shè)計(jì).124.1INTERFACES: 接口.124.2PNEUMATIC PLAN氣動(dòng)圖.12 5ELECTRICAL DESIGN電氣設(shè)計(jì).135.1INTERFACES: 接口.135.2WIRING DIAGRAM線路圖.13 5.3DOCUMENTATION OF MEASURING EQUIPMENT測(cè)量設(shè)備文

5、件.136FOG MACHINE煙霧器.14 Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 3 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-001Document Revision History文件修訂歷史文件修訂歷史1.1Change Control更改控制更改控制This document is maintained under change control. Any requests for c

6、hange should go to:文件受更改控制。任何更改要求都應(yīng)該發(fā)給:Franz HaiderUltimate Europe Transportation Equipment GmbHFranz Kollmann-Str. 4A-3300 AmstettenPhone:+43 (0) 7472 / 65510-137Fax:+43 (0) 7472 / 65510-70e-mail:franz.haiderultimate-web:www.ultimate-1.2Confidentiality and Copyright 機(jī)密性和版權(quán)機(jī)密性和版權(quán) Copyright Ultimate

7、Europe Transportation Equipment GmbH . All rights reserved.歐特美歐洲公司版權(quán). 保留所有權(quán)力。No part of this document may be reproduced in any form without the prior written permission of Ultimate Europe Transportation Equipment GmbH未經(jīng)歐洲公司以書面形式允許，不能以任何形式拷貝此文件的任何部分。IssueDateAuthorDescription002007-05-18F. HaiderOrig

8、inalAuthor:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 4 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-002Aim of Pressure Tightness Mock Up 氣密試驗(yàn)工裝目的氣密試驗(yàn)工裝目的The aim of Mock Up Design is to fulfill following requirements:設(shè)計(jì)工裝的目的是為了達(dá)到以下要求：2.1General Space Re

9、quests總的空間要求總的空間要求Mock Up has to be engineered in a modular way, so that known biggest gangways can be tested.Therefore only different flange plates have to be mounted to mock up frame.Considered gangways:工裝必須以模塊化方式設(shè)計(jì)，可以測(cè)試已知的最大風(fēng)擋。因此只需安裝不同的法蘭板到工裝框上。考慮的風(fēng)擋：-Railjet G-0155-01_02-Ile de France: G-0117-BO

10、M-01-01-X60: G-0017-01.01-SSL: G-0149-02-13The mock up should be designed, so that simulated car end bodies can be assembled in a distance from each other from 400 to 1450mm.工裝應(yīng)設(shè)計(jì)成模擬的安裝車端距范圍在400-1450mm之間。2.2Requests of UIC 660:UIC 660 要求要求To fulfill requirements of further projects also standard UIC

11、 660 has to be considered.To demonstrate that the gangway design offers sufficient strength and resistance to aerodynamic peak stress levels (tunnel), the mock up must be shown in a single trial to meet the following requirements:The gangway bellow shall withstand 要達(dá)到其他項(xiàng)目的要求也必須考慮UIC 660標(biāo)準(zhǔn)。為了證明風(fēng)擋的設(shè)計(jì)具

12、有足夠的強(qiáng)度和抵抗力達(dá)到空氣動(dòng)力學(xué)峰值應(yīng)力水平（隧道），工裝必須在單獨(dú)的測(cè)試中展示符合以下要求：風(fēng)擋折棚能夠抵抗-a positive pressure differential outside to inside of +5150Pa and 從外到內(nèi)正壓差為+5150Pa-a negative pressure differential outside to inside of -8100Pa -during 2,5 seconds. 在 2.5 秒內(nèi)從外到內(nèi)的負(fù)壓差為-8100PaAuthor:Franz HaiderIssue:00Date first issue:2007-05-18

13、Pg No: 5 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-002.3Requests of Project Railjet:Railjet項(xiàng)目要求：項(xiàng)目要求：Whole Gangway has to be assembled into Mock Up. The interface of car end bodies to gangway has to be simulated as far as practicable. Therefore the test volume

14、of gangway is approximately 2,5m3.整個(gè)風(fēng)擋必須組裝到工裝上，車端與風(fēng)擋的接口的模擬必須盡可能實(shí)際。因此風(fēng)擋的測(cè)試容積大約為2.5 m32.3.1Type Test Requests型式試驗(yàn)要求：型式試驗(yàn)要求：-Check of mechanical stiffness of gangway at +6000Pa.檢驗(yàn)+6000Pa 時(shí)風(fēng)擋的機(jī)械硬度-Check of mechanical stiffness of gangway at -6000Pa. 檢驗(yàn)-6000Pa 時(shí)風(fēng)擋的機(jī)械硬度-Time for Pressure difference change

15、 from +4000Pa to +2200Pa greater than 60s. 壓差從+4000Pa 變化到+2200Pa 的時(shí)間大于 60 秒-Time for Pressure difference change from -4000Pa to -2200Pa greater than 60s 壓差從-4000Pa 變化到 -2200Pa 的時(shí)間大于 60 秒-Volume Change of gangway bellow has to be documented with fotos for pressures +-500Pa, +-1000Pa, +-2000Pa and +-4

16、000Pa. Additionally the max. bellow material deflection have to be measured (Position difference of bellow under pressure to bellow in nominal situation).風(fēng)擋折棚的容積變化必須在文件中附有壓力為+-500Pa, +-1000Pa, +-2000Pa 和+-4000Pa時(shí)的照片。另外，必須測(cè)出折棚材料的最大變形量（額定狀態(tài)下，折棚受壓時(shí)的位差）。-Volume Change less than 50 dm3 at +1000Pa. +1000P

17、a時(shí)，容積變化少于50分米2.3.2Routine Requests 常規(guī)要求常規(guī)要求-Time for Pressure difference change from +4000Pa to +2200Pa greater than 60s.壓差從+4000Pa 變化到+2200Pa的時(shí)間大于60秒-Time for Pressure difference change from -4000Pa to -2200Pa greater than 60s 壓差從-4000Pa 變化到 -2200Pa 的時(shí)間大于 60 秒2.4Requests of Project SSL: SSL項(xiàng)目要求：項(xiàng)目要

18、求：2.4.1Type Test Requests型式試驗(yàn)要求型式試驗(yàn)要求Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 6 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-00-Check of mechanical stiffness of gangway at +2500Pa without permanent deformation and no exceeding of elastic limits

19、. SSL Specification GWY-T-04615 +2500Pa時(shí)，風(fēng)擋的機(jī)械硬度檢測(cè)，沒有永久變形和過度的彈性限制 SSL 規(guī)范 GWY-T-04615-Check of mechanical stiffness of gangway at -2500Pa without permanent deformation and no exceeding of elastic limits. SSL Specification GWY-T-07408 +2500Pa時(shí)，風(fēng)擋的機(jī)械硬度檢測(cè)，沒有永久變形和過度的彈性限制 SSL 規(guī)范GWY-T-074082.4.2Routine Req

20、uests 常規(guī)要求常規(guī)要求-No Request沒有要求Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 7 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-003Mechanical Design機(jī)械設(shè)計(jì)機(jī)械設(shè)計(jì)The mock up is designed to fulfill gangway testing according Space Requirements defined in Item 2.1

21、. 按照 2.1 項(xiàng)規(guī)定的空間要求，設(shè)計(jì)工裝進(jìn)行風(fēng)擋試驗(yàn)。Design Stiffness is done to fulfill pressure difference loads of max. +-10000Pa (=+-0,1 bar). 設(shè)計(jì)硬度達(dá)到最大為+-10000Pa (=+-0,1 bar) 的壓差負(fù)荷。Then Safety valves have to work and stress of mock up design is in a well area (up to 80% of yield stress for frame material S235.)安全閥必須運(yùn)行，

22、工裝設(shè)計(jì)的應(yīng)力處于適當(dāng)區(qū)域（達(dá)到框架材料 S235 屈服應(yīng)力的 80%）。3.1Fixed Mock Up Half:固定的半工裝固定的半工裝Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 8 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-00Design consists of Welded Steel Profiles (S235) and the flange plate (4mm thick S23

23、5 plate) for the gangway. This flange plate is riveted to the frame.工裝設(shè)計(jì)由焊接鋼質(zhì)型材（S235)和 風(fēng)擋法蘭模板（4mm 厚的 S235 板）組成。法蘭模板鉚接在框架上。The shown flange plate is for Project Railjet. For Testing of other gangways new flange plates with the special project interface have to be produced. 所示法蘭模板用于 Railjet 項(xiàng)目。其他風(fēng)擋的試驗(yàn)

24、，必須生產(chǎn)帶有特殊項(xiàng)目接口的新法蘭模板。Additionally brackets (ladder) should be welded to flange plate, so that the Accessibility of upper clamps is also guaranteed.另外，應(yīng)該將支架（梯子）焊接到法蘭模板上，這樣也容易接近上夾具。Fixing of Gangway in Mock Up:將風(fēng)擋固定在工裝上：For type test standard fixing of gangway to flange plates can be done via same scre

25、ws as by connection to car structure. Then test with highest loads (up to 8100Pa can be done).針對(duì)型式試驗(yàn)標(biāo)準(zhǔn)，運(yùn)用與將風(fēng)擋固定在車結(jié)構(gòu)上相同的螺釘將風(fēng)擋固定在法蘭板上。接著用最大負(fù)荷進(jìn)行試驗(yàn)（可以達(dá)到 8100 Pa）。For routine test additionally following quick fastening system has been developed. The position of the end frames is defined via fix assembled

26、 bolts in flange plate. By use of clamps the necessary pressure between end frames and flange plate can be reached. This solution can be used for routine test up to 4000Pa. 已經(jīng)另外開發(fā)了用于常規(guī)試驗(yàn)的以下快速緊固系統(tǒng)。通過固定組裝螺栓在法蘭模板上限定端框的位置。通過運(yùn)用夾具，可以達(dá)到端框和法蘭模板之間必需的壓力。這一解決方案可用于達(dá)到 4000Pa 的常規(guī)試驗(yàn)。Author:Franz HaiderIssue:00Date

27、 first issue:2007-05-18Pg No: 9 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-00Clamps will be delivered b y EUTM to QUTM, but adapter part has do be manufactured by QUTM.歐洲歐特美將夾具交付給青島歐特美，但襯套部歐洲歐特美將夾具交付給青島歐特美，但襯套部件應(yīng)該由青島歐特美生產(chǎn)。件應(yīng)該由青島歐特美生產(chǎn)。Adapter Part:襯套部件襯套部件Simulat

28、ion of Coupler:車鉤模擬車鉤模擬The middle frame of gangway will be supported by a “simulated coupler”.Please manufacture contact part from plastic, so that no surface damage happens during testing.風(fēng)擋對(duì)接框由一個(gè)“模擬車溝”支撐。請(qǐng)用塑料制造接觸件，這樣在實(shí)驗(yàn)中就不會(huì)出現(xiàn)表面損壞。Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 10 of 1

29、4Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-00Moveable Mock Up Half:活動(dòng)的半工裝活動(dòng)的半工裝Moveable Mock Up half consists of welded frame, flange plate and door.活動(dòng)的半工裝由焊接框，法蘭模板和門組成。The door is necessary for accessibility of gangway fixing elements of flange plate. 為接近法蘭模板的風(fēng)擋固定部

30、件，門是必需的。Additionally brackets should be welded to flange plate for better accessibility of upper clamps.另外，為更加接近上夾具，應(yīng)該將支架焊接到法蘭模板上。The moveable Mock Up half is connected via screws to lower two I-Profiles. Distance via flange plates is engineered to 822mm for project Railjet. For other projects new h

31、oles in I-Profiles have to be drilled.活動(dòng)的半工裝通過螺釘連接到底部的兩個(gè) I-型材。用于 Railjet 項(xiàng)目的法蘭模板之間的距離設(shè)計(jì)成 822 mm。用于其他項(xiàng)目時(shí)，必須在 I-型材上重新鉆孔。3.2Connection between two Mock Up Halves:兩個(gè)半工裝之間的連接兩個(gè)半工裝之間的連接4 Connecting Rods fix the 2 halves together, which allow pressure difference between outside to inside from +-10000Pa (+-

32、0,1 bar). The design of connecting rods allow quick connecting and disconnecting. This is necessary for better exchange of gangways in case of routine test.No pressure test is allowed without these connecting rods!用 4 個(gè)連接桿把兩個(gè)半工裝固定在一起，允許從外到內(nèi)的壓差為+-10000Pa (+-0,1 bar)。連接桿的設(shè)計(jì)允許快速聯(lián)掛和解掛。如果進(jìn)行常規(guī)試驗(yàn)，這對(duì)于更好的更換風(fēng)

33、擋是必須的。Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 11 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-00沒有連接桿不允許進(jìn)行壓力試驗(yàn)。The shown connection rod consists of two pipes and a threaded bolt with right and left hand thread. It is engineered so that gangway

34、 width of 400mm to 850mm can be adjusted. For higher Gangway width up to 1450mm a longer threaded bolt has to be developed.所示的連接桿由兩根管和一個(gè)帶有左右手動(dòng)螺紋的攻絲螺栓組成。連接桿應(yīng)該能夠調(diào)整從 400mm 到 850mm 的風(fēng)擋寬度。對(duì)于寬度達(dá)到 1450mm 的較高的風(fēng)擋，應(yīng)該開發(fā)較長的攻絲螺栓。3.3Desk Design臺(tái)面設(shè)計(jì)臺(tái)面設(shè)計(jì)On fixed Mock Up half a desk should be produced so that pneuma

35、tic and electrical components can be hidden inside. On the desk top surface computer system for automatically measurement will be placed.制造一個(gè)臺(tái)面安裝在固定的半工裝上，使氣動(dòng)的和電動(dòng)的元件可以隱藏在里面。在試驗(yàn)臺(tái)的頂部表面安裝進(jìn)行自動(dòng)測(cè)量的計(jì)算機(jī)系統(tǒng)。Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 12 of 14Checked:Title:Pressure Tightness Mo

36、ck Up DescriptionDocument No.:G-8560-100-004Pneumatical Design氣動(dòng)設(shè)計(jì)氣動(dòng)設(shè)計(jì)4.1Interfaces:接口接口Over Pressure Safety Valve: ”在壓力安全閥以上：”Vacuum Relief Valve: ”真空緩和閥：”Flexible Over Pressure Tubing Interface: ”壓管接口以上可彎曲：”Flexible Under Pressure Tubing Interface: ”壓管接口以下可彎曲：”Quick Exhaust Valve Interface:”快速排氣閥接

37、口：”Please provide Threaded holes as defined for pneumatic components. The whole pneumatic components (blue components) will be supplied premounted from EUTM to QUTM.請(qǐng)?zhí)峁┯糜跉鈩?dòng)部件的規(guī)定的攻絲孔。EUTM 為 QUTM 提供進(jìn)行預(yù)安裝的整個(gè)氣動(dòng)部件（藍(lán)色部件）。4.2Pneumatic Plan氣動(dòng)計(jì)劃氣動(dòng)計(jì)劃 Final definition after set up of pneumatic components.設(shè)定氣動(dòng)部件后將最終定義。Author:Franz HaiderIssue:00Date first issue:2007-05-18Pg No: 13 of 14Checked:Title:Pressure Tightness Mock Up DescriptionDocument No.:G-8560-100-005Electrical Design電動(dòng)設(shè)計(jì)電動(dòng)設(shè)計(jì)5.1Interfaces:接口接口Electrical Adapter Plate: Flan