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Transportation: Railway-Trains, Trams, Tube

  • Transportation: Railway-Trains, Trams, Tube
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Modern train travel and transportation dates back to the 1820's, when rail lines began to connect cities together and provide a means of moving both products and people from one place to another over steel rails laid on specially prepared road beds. Cars and coaches were attached to steam locomotives, which remained the basic power source for the next 100 years. Today trains provide high load capacities, energy efficiency, and transport at faster speeds than ever. Trains are not limited to just wide open spaces, when a rail vehicle runs for at least part of the time on city streets, it's called a tram. When improved methods of underground boring were developed, making it possible to bore tunnels at considerable depths beneath power, water and sewer system infrastructure, tube trains made the process of "cut and cover" construction for underground trains irrelevant.

 

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Overview

Railway - Trains, Trams, Tube

Railway - Trains, Trams, Tube

Today's rail transportation manufacturer, as with other major transportation sectors, looks to take advantage of new stronger light weight construction materials, such as aluminum, to reduce fuel costs and improve the strength to weight ratio of passenger cars, coaches, and tramcars, as well as to take advantage of modern design and construction methods driven by CAD/CAM software and CNC processes: improving the time from concept to build, increasing flexibility in design, and reducing labor content in production and assembly.

CMS' large format, heavy duty, CNC machining centers provide power, precision and broad processing abilities for machining passenger car side and roof structures, including the machining of the individual components used to build up of these assemblies, as well as the machining of the structures after fabrication including the edge trimming, milling of window and door openings, related hole drilling and tapping operations, as well as CMS' specialized CNC process of locating and machining the weld bead left over from the fabrication of the components into the structural assemblies, a unique CNC machining process, combining high tech software and probing equipment, which not only eliminates a significant amount of manual labor, but results in a sleek, glistening, high tech, exterior finish.

Moving
gantry CNC's

MBB - large format CNC machining for train car sides

MBB - large format CNC machining for train car sides

MBB, CMS' moving gantry class CNC machining center, has been provided with CMS' special CNC controlled rail and clamping system for the long length extrusion machining needs of train car side and roof assemblies, making it possible to reference, clamp, and securely hold assemblies of various lengths and widths. The CNC rails and clamps are given instructions as to where to position themselves for securely holding the side or roof. MBB's heavy duty machining power is supplied by CMS', 5-axis, KX5 working unit, capable of complex machining operations and supported with an oil mist unit for milling, routing, slotting, drilling, tapping and sawing operations. Beneath MBB's rail and clamping system is located its power take away chip and scrap conveyor system.

The photo shows the side of a train car, which is itself an heavy, welded, aluminum extrusion assembly, as it is following the conclusion of machining processes, in which the ends have been trimmed, the openings for windows milled, the required holes drilled and tapped, and prior to the start of the cycle, the surface has been probed to determine the surface location and position of the seam welds. The weld information, quickly obtained in this special cycle, is used to update MBB's CNC machining program and then to mill the welds off, resulting in a smooth exterior finish, eliminating the need of an otherwise significant manual process, with its labor.

MBB is equipped with:

  • CMS' KX5 5-axis working unit, with 28 kW (37.5 hp) power spindle at 4,300 rpm S1 rating, 24,000 rpm maximum, liquid cooled
  • tapping aggregates
  • radio probe for weld removal process
  • oil mist unit CMS' CNC controlled rail and clamping table
PMT - large format, moving gantry, CNC machining for train sides and roofs

PMT - large format, moving gantry, CNC machining for train sides and roofs

PMT, CMS' moving gantry class CNC machining center, provides the 5-axis working envelop size and power needed for machining the large side and roof sub-assemblies utilized in trains, trams and tube passenger cars. PMT's design makes it possible to machine very long welded aluminum extruded assemblies. PMT reaches lengths of up to 60+ meters (~197'), easily providing the length needed for pendular cycles, if so required, where concurrent setup on one end of the machine takes place, while work continues on the other. PMT's design also makes it easy for loading and unloading large panels, and is easily accessible for a crane.

PMT is equipped with CMS' powerful, 5-axis, KX5 working unit with 28 kW (37.5 hp) power spindle at 4,300 rpm S1 rating, maximum 24,000 rpm, liquid cooled, for use with milling, drilling and taping equipment, and available with oil mist lubrication or full flood system.

The picture to the left shows PMT with its moving gantry, low rail, guide ways system, long working table, and without its protective barrier for ease of view. To the right, PMT is shown with its perimeter protection enclosure, with access from either end and viewing windows from the side.

Moving
bridge CNC's

Poseidon - large format, heavy duty machining for train sides and roofs

Poseidon - large format, heavy duty machining for train sides and roofs

Poseidon, CMS' moving bridge class CNC controlled machining center, meets the requirement for the broad range of machining needs for train side and roof assemblies, providing even larger working envelops, heavy duty 5-axis machining power, oil mist or full flood processing capabilities, and can be equipped with CMS' special CNC controlled work piece rail and clamping table, cast iron working table, or CMS' steelwork fabricated tables for special requirements.

Poseidon's basic working envelop and working head characteristics are:

Strokes:
  • From X axis 2.5 m to 41.0 m (8.2' to 134.5')
  • From Y axis 2.6 m to 8.5 m (8.5' to 27.9')
  • From Z axis 1.3 m to 4.0 m (4.3' to 13.1'), non-telescopic version standard and telescopic versions available where reduced height limitations exist Working units:
  • From PX5 working unit with 12 kW power (16.1 hp) at 12,000 rpm, maximum 24,000, liquid cooled, S1 rating, A axis +/- 120°, C axis +/- 270°
  • To KX5 working unit with 15 kW power (20.1 hp) at 12,000 rpm, maximum 24,000, liquid cooled, S1 rating, A axis +/- 120°, C axis +/- 270°
  • To KX5 working unit with 28 kW power (37.5 hp) at 4,300 rpm, maximum 24,000, liquid cooled, S1 rating, A axis +/- 120°, C axis +/- 270° 16 place tool changing magazine standard, with additional expansion possible

Images

Passenger cars connected together for fast, convenient, transportation

Passenger cars connected together for fast, convenient, transportation

Passenger cars connected together in high speed train, tram and tube settings are essential conveyance systems within today's large cities, and increasingly are being used to connect them together, providing more traveling options, and a strategy for the long term underlying growth demands of transportation. CMS' advanced CNC machining center technology for train, tram and tube cars is providing the underlying support for that future... today.

Fully assembled high speed train passenger car

Fully assembled high speed train passenger car

This photo shows the side of a fully assembled high speed train passenger car following the machining process, in which the ends have been trimmed, the window and door openings milled to size, the holes drilled and tapped, and with a sleek, finished exterior surface, resulting from CMS' unique weld milling process.

In the photo to the bottom left, the car side is shown with a continuous weld along the joints where the sections have been joined together, about 10 mm in width.

The photo to the bottom right shows this joint surface following CMS' unique machining process, which probes to determine the weld location, and updates the CNC machining program, following which the weld is milled down to match the surface, resulting in a seamless, smooth, continuous exterior.
 

Massive sub-assemblies and their fabrication

Massive sub-assemblies and their fabrication

Massive sub-assemblies for train floors, roofs, and sides are manipulated through the fabrication process. These structures, though large and heavy, move easily through CMS' large format CNC machining centers.