Process Management of Adhesive Bonding in Rail Vehicle Construction

Transcription

1 Process Management of Adhesive Bonding in Rail Vehicle Construction Seite 1

2 Einsatz Prologue von Zitaten Erwünschte Dinge treten nur ein, wenn sie geplant wurden; unerwünschte Dinge stellen sich von selbst ein. Zitat Philip B. Crosby Seite 2

3 DIN 6701 Bonding of rail vehicles and rail vehicle parts Part 1: Basic terms, basic rules unpublished preliminary draft will be dealt with at the end Part 2: Qualification of the user companies has been released since 2006 defines the requirements on the manufacturers basis for company certification Part 3: Guideline for the construction and verification published draft since describes the procedure for construction and verification Part 4: Implementation rules and quality assurance published draft since describes the procedure for manufacture and quality assurance Seite 3

4 Guideline bonding supervision Tasks, responsibilities and competencies Personnel qualification Integration into R&D Quotation review Support for construction Documents concerning adhesive bonding Construction review Supplier management Planning of bonding process Manufacturing documents Monitoring of manufacture Logistics Seite 4

5 Certification The Siemens site Krefeld Uerdingen has been certified according to DIN 6701 part 2 since for A1 bondings in rail vehicle construction Seite 5

6 Personnel qualification vkap development area qualification EAE representative of the vkap qualification EAE KAP interior construction qualification EAS 60% of all component constructors trained in-house 20% of all assembly staff are EAB s 50% of all assembly staff trained in-house KAP: vkap: KAP driver s cabin qualification EAS KAP shell construction qualification EAS bonding supervisor responsible bonding supervisor vkap factory qualification EAE representative of the vkap qualification EAE KAP QM area assembly qualification EAS KAP QM area shell construction qualification EAS KAP QM area supplier qualification EAS KAP process planning qualification EAS Seite 6

7 Classification Classification of the bonded joints Depending on the safety-related, functional and economic significance of the bonded joint, a division into classes is done on the basis of a failure sequence analysis The class determines, for instance, the effort necessary in development, design and qualification the measures for designing and assuring the bonding process Kennzeichnung der Planungsunterlagen The training level of the staff involved in the overall process Seite 7

8 List with requirements on bonded joints Breaking down the requirements of the total vehicle to the bonded joint They include the whole product life cycle The list of requirements is the basis for layout and design of the bonded joints as well as the selection of the adhesion system Input is provided by the following areas: customer specifications standards engineering quality management process planning purchase logistics customer service Seite 8

9 Verification Verification: to show that a bonded joint meets the requirements in all life cycles over the planned duration of use. Possibilities: verification that load is smaller than load capacity testing of component documented experiences combination of the three means Is not limited to the strength test during operation. Depending on the application, liability, media resistance, manufacturing stresses have also to be considered. Seite 9

10 Stress analysis Stresses of the overall structure Load cases from rules and standards (DIN EN 12663, UIC 566, DIN EN 15227, ) Field data (information from real-life operation) Calculation Local stress of the adhesive joint from the stress of the overall structure Validation of the calculation Component tests (pressure cycle test) Measurement of the relative movement of bonded components during vehicle operation inductive travel sensor vehicle box gauge block, connected rigidly to window side window Seite 10

11 Stress capability State-of-the-art: Determination of the reduction factors by stresses in individual tests Multiplication of the reduction factors with nominal value stress capability Adhesion and cohesion are investigated separately Future state-of-the-art: Determine stress capability from relevant stress combinations Adhesion and cohesion are investigated separately Stress < stress capability Operational strength 30 years! Pull shear specimens for el. thick-layer bonding fixed with defined strain Specimens for relaxation test Seite 11

12 Assessment of bids and design Review system in the design process Bid Design Review (BDR) Bid can be implemented Conceptual Design Review (CDR) Bonded joints specified Design Review (DR) Classes determined Lists of requirements established Design Freeze (DF) Verification tests specified Design of adhesive seam joint approved Design Approval (DA) Verification completed Planning documents approved Seite 12

13 Planning documents 3D Model Complete 3D data. Serves as planning basis for work scheduling Mounting document Documentation of the class Specification of the joining surfaces Definition of tolerances for joined parts and adhesive joint Description of the form, location and dimension of the adhesive joint Specification of the pre-treatment process Definition of QS measures Seite 13

14 Planning of adhesive process Manufacturing environment Light Cleanliness Dirt accumulation higher cleaning effort Manufacturing process Existing infrastructure Place Storage space Environment Temperature or humidity increase fixing time and downtime use accelerated systems Environment Temperature or humidity reduce skin-forming time or open time Seite 14

15 Planning of bonding process Manufacturing facilities Manufacturing facilities: Facilities for provision of adhesives and application Transport, positioning, fixing devices Platform technology, special tools Measuring instruments, measuring devices must be planned, acquired, qualified, maintained and in part calibrated Objective: optimization of Quality and effectiveness of the manufacturing process Ergonomics Occupational safety Seite 15

16 Manufacturing documents Bonding process is an integral part of the work schedule of the assembly group Qualification specifications for performing parties Adhesive surface specification (identifiable for the performing party) Material list Reference to safety instructions General references Specifications for process assurance Adhesive process (detailed, illustrated, tools and devices) Electronic provision incl. 3D model to performing staff Seite 16

17 General quality specifications Q measures depending on component class A1 - performing EAB - company-specific operating instruction - quality stopping point - checking of ambient conditions - checking of best-before date - bonding protocol - adhesion test monitoring production A2 - performing EAB - company-specific operating instruction - quality reporting point - checking of ambient conditions - checking of best-before date - bonding protocol - adhesion test monitoring production small sample size A3 - performing party in-house training - construction specification - checking of ambient conditions - checking of best-before date No class - construction specification - checking of ambient conditions - checking of best-before date Seite 17

18 Process documentation Bonding protocol: Documentation requirement Allocation of adhesive materials to the bonding process (batch number) Process assurance (check list of important characteristics, e.g. visual test of the surfaces) Recording of the test result of the work sample during production Description of measures in the case of interferences in the process (signed by the KAP) Possibly customer specifications Seite 18

19 Monitoring quality assurance Depending on the component class, stopping points are allocated to bonding components in an EDP system. For every production order, a testing order is generated from this: Quality stopping point: production reports bonding components to quality assurance, process monitoring compulsory Quality reporting point : production reports bonding components to quality assurance, process monitoring system-supported optional In the case of process deviations, the bonding supervision must be consulted. They decide on necessary measures. Seite 19

20 Einsatz Epiloguevon Zitaten ue Es gibt absolut keinen Grund, warum ein Produkt oder eine Dienstleistung Fehler oder Mängel Zitat Philip B. Crosby aufweisen sollte. Siemens AG 2011 Seite 20