DESC:CROSS REFERENCE TO RELATED APPLICATION
This application is based on and derives the benefit of Indian Provisional Application 201921053101 filed on 20/12/2019, the contents of which are incorporated herein by reference.

TECHNICAL FIELD
[001] The embodiments herein relates generally to railway vehicle manufacturing facility, more particularly to a universal assembly fixture and a method for manufacturing a coach of a railway vehicle.

BACKGROUND
[002] Generally, a train is a form of rail transport consisting of a series of connected vehicles that generally run along a railroad track to transport cargo and/or passengers. The typical passenger railway car in use today ranges in length from 30 to 85 feet and can easily weigh between 20,000 pounds to 200,000 pounds. Weight reduction is a significant concern, and as a result, lightweight materials, including aluminum framing and outer skins or shells are preferred since the lighter is the weight of the rail car, the more fuel efficient is the passenger carrying operation.
[003] The typical railway car shell is constructed around a basic sub frame component which can be generally described as a U-shaped sub frame assembly having two vertical sidewall posts interconnected by a curved carline which functions as a roof support frame member or roof truss. Each shaped frame member is individually crafted, and welded in place to the side sills of the floor assembly, and interconnected, one to the other, usually by welding interconnecting door and window headers and sills. Once the car shell frame is assembled, the outer skin is attached and it is fixed in place to the under-frame and the rail wheel bogies.
[004] Usually each car shell is individually fabricated piece by piece. This takes considerable skill on the part of a craftsman in aligning and insuring that the side posts and carlines are properly placed to insure that the finished railway car shell is plumb and within dimensional tolerances. One of the main costs in the construction of railway cars relates to the labor involved and assembling time required for assembling. In railway cars of the type illustrated above, the individual components may be packaged and shipped while separated. They may be then assembled by bolting the individual components together. Such bolting, while requiring care, does not require as high a degree of skill as welding. For example, where highly skilled help is in short supply, bolting of the components may be desired. On the other hand, some customers may wish to weld the components together by conventional welding means and utilize local labor for assembly rather than that of the manufacturer's. If mass production techniques are to be employed in order to keep the costs of manufacture of components to a minimum, it is desirable that the basic components to a minimum, and it is also desirable that the basic components manufactured be capable of being assembled by either bolting or welding. Further, it is desirable that the car or shell be capable of assembling easily in a row, without changing the basic structural components.
[005] Therefore, there exists a need for a universal assembly fixture and method for manufacturing a coach of a railway vehicle, which obviates the aforementioned drawbacks.

OBJECTS
[006] The principal object of embodiments herein is to provide a universal assembly fixture for manufacturing a coach of a railway vehicle.
[007] Another object of embodiments herein is to provide a method for manufacturing a coach of a railway vehicle.
[008] Another object of embodiments herein is to provide the universal assembly fixture which is adapted to facilitate automatic welding of parts of the railway vehicle for fabricating the coach.
[009] Another object of embodiments herein is to provide the universal assembly fixture which facilitates in easy manufacturing of the coach of the railway vehicle such as a train.
[0010] Another object of embodiments herein is to provide the universal assembly fixture which facilitates in reducing time required for manufacturing the coach of the railway vehicle.
[0011] Another object of embodiments herein is to provide the universal assembly fixture which is adapted to manufacture coach having different width by providing a movable platform and movable side clamps on either sides of the coach.
[0012] Another object of embodiments herein is to provide the universal assembly fixture for manufacturing at least one of a mainline electrical multiple unit (MEMU) coach, an electrical multiple unit (EMU) coach, a Linke Hofmann Busch (LHB) coach of the railway vehicle.
[0013] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0014] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0015] Figs. 1a and 1b depict a perspective views of a universal assembly fixture for manufacturing a coach of a railway vehicle, according to embodiments as disclosed herein;
[0016] Figs. 2a and 2b depict a perspective views of a platform support pillar and sliding arrangement for a movable platform, according to embodiments as disclosed herein;
[0017] Fig. 3 depicts a perspective view of a side wall clamp of the universal assembly fixture, according to embodiments as disclosed herein;
[0018] Fig. 4 depicts a perspective view of a sidewall and under-frame joint clamp and an under frame resting pads, according to embodiments as disclosed herein;
[0019] Figs. 5a and 5b depict a perspective view of lifting jack, according to embodiments as disclosed herein;
[0020] Fig. 6 depicts a perspective view of a welding track arrangement and a welder, according to embodiments as disclosed herein;
[0021] Figs. 7a and 7b depict a perspective view of sidewall window area clamps, according to embodiments as disclosed herein;
[0022] Fig. 8 depicts a perspective view of a dummy bogie of the universal assembly fixture, according to embodiments as disclosed herein;
[0023] Fig. 9 depicts a perspective view of a camber removing arrangement of the universal assembly fixture, according to embodiments as disclosed herein; and
[0024] Fig. 10 depicts a flowchart indicating a method for manufacturing a coach of a railway vehicle, according to embodiments as disclosed herein.

DETAILED DESCRIPTION
[0025] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0026] The embodiments herein achieve a universal assembly fixture for manufacturing a coach of a railway vehicle. Further, the embodiments herein achieve a method for manufacturing a coach of a railway vehicle. Furthermore, the embodiments herein achieve the universal assembly fixture which is adapted to facilitate automatic welding of the parts of the railway vehicle for fabricating the coach. Additionally, the embodiments herein achieve the universal assembly fixture which facilitates in easy manufacturing of the coach of the railway vehicle such as a train. Moreover, the embodiments herein achieve the universal assembly fixture which facilitates in reducing time required for manufacturing the coach of the railway vehicle. The embodiments herein achieve the universal assembly fixture which is adapted to manufacture coach having different width by providing a movable platform and side clamps on either sides of the coach. Also, the embodiments herein achieve the universal assembly fixture for manufacturing at least one of a mainline electrical multiple unit (MEMU) coach, an electrical multiple unit (EMU) coach, a Linke Hofmann Busch (LHB) coach of the railway vehicle. Referring now to the drawings Figs 1 through 10, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0027] For the purpose of this description and ease of understanding, the universal assembly fixture (100) is adapted for making at least one of a mainline electrical multiple unit (MEMU) coach, an electrical multiple unit (EMU) coach, a Linke Hofmann Busch (LHB)of a vehicle such as a train. However, it is also within the scope of this invention to practice/ implement the universal assembly fixture (100) for making any other type of coaches of vehicles such as bus, metro trains, trams and any other type of transport vehicles without otherwise deterring the intended function of the universal assembly fixture (100) as can be deduced from the description and corresponding drawings. The coach is made up of a roof, an end wall, a front wall, two sidewalls, and an under-frame. These parts are first assembled, rigidly secured using clamps in the universal assembly fixture and then subsequently welded through set up of auto welders for seamless welding.
[0028] Figs. 1a and 1b depict perspective views of a universal assembly fixture for manufacturing a coach of a railway vehicle, according to embodiments as disclosed herein. In an embodiment, the universal assembly fixture (100) includes a plurality of platform support pillars (102), a first movable platform (104), at least one side wall clamp (106), a plurality of sidewall and under-frame joint clamps (108) (as shown in Fig. 4), a plurality of under frame resting pads (110) (as shown in Fig. 4), a plurality of lifting jacks (112) (as shown in Figs. 5a and 5b), a weld track arrangement (114) (as shown in Fig. 6), a welding device (116) (as shown in Fig. 6), a controller (118) (not shown), a power source (120) (as shown in Fig. 6), a changeover stopper (122), a plurality of sidewall window area clamps (124) (as shown in Figs. 7a and 7b), a second platform (126) (as shown in Fig. 2), a plurality of dummy bogie (128) (as shown in Fig. 8), and side railing (130).
[0029] Figs. 2a and 2b depict perspective views of a platform support pillar and sliding arrangement for a movable platform, according to embodiments as disclosed herein. The universal assembly fixture (100) includes the plurality of platform support pillars (102) mounted above a ground surface. The plurality of platform support pillars (102) disposed in two rows which are parallel and define a predetermined gap there between. Further, each of the platform support pillars (102) includes a first pillar (102a) disposed towards an exterior side of the plurality of platform support pillars (102) and a second pillar (102b) disposed towards an interior side of the plurality of platform support pillars (102). The Further, the first pillar (102a) and second pillar (102b) are adapted to support the movable platform (104). Further, each of the platform support pillar (102) includes a connecting member (102c) connecting the first pillar (102a) and the second pillar (102b). Furthermore, each of the platform support pillar (102) includes at least one sliding track (102s) defined at an upper end of the platform support pillar (102). The sliding track (102s) is adapted to support the first movable platform (104).
[0030] Further, the universal assembly fixture (100) includes the first movable platform (104) which is adapted to slide in the sliding track (102s) to move from a distal end to a proximal end and vice-versa. The movable platform (104) is configured to slide within a predetermined distance defined by the sliding track (102s). Each of the first movable platform (104) is connected with an actuating means (104a) to move the movable platform (104) from the distal end to the proximal end and vice-versa. The actuating means (104a) is actuated by the controller (118) based on the width of the coach. In an embodiment, the actuating means (104a) is at least a hydraulic actuator. However, it is also within the scope of this invention to practice/ implement any type of actuating means without otherwise deterring the intended function of the universal assembly fixture (100) as can be deduced from the description and corresponding drawings. Further, the first movable platform (104) is connected to the weld track arrangement (114) at one side and the side railing (130) on the other side. The side railing (130) is installed on one side of the first movable platform (104) to provide safety to an operator. Furthermore, the first movable platform (104) includes the changeover stopper (122) to accommodate a predetermined width of the railway vehicle within the gap defined between the rows of plurality of platform support pillars (102).
[0031] Fig. 3 depicts a perspective view of a side wall clamp of the universal assembly fixture, according to embodiments as disclosed herein. The universal assembly fixture (100) includes the at least one side wall clamp (106) which disposed below the first movable platform (104) and connected to the actuating means (104a). The side wall clamp (106) is disposed towards the interior side of each of the corresponding platform support pillar (102). Each of the side wall clamp (106) is connected to the first movable platform (104) such that a clamping face (106a) of the side wall clamp (106) is disposed towards the gap defined between the plurality of platform support pillars (102). The side wall clamp (106) is adapted to facilitate gauging (coach width) and holding sidewall of the coach. The side wall clamp (106) is connected to the actuating means (104a), whereby the slide wall clamp (106) is configured to move between an unclamping position and a clamping position and vice-versa. Further, the universal assembly fixture (100) includes a plurality of front wall clamps and a plurality of rear wall clamps which are configured to hold the front wall and the rear wall at a predetermined position during manufacturing of the coach.
[0032] Fig. 4 depicts a perspective view of a sidewall and under-frame joint clamp and an under frame resting pads, according to embodiments as disclosed herein. The universal assembly fixture (100) further includes the plurality of sidewall and under-frame joint clamps (108) which is adapted to hold the side wall and the under-frame in a predetermined position for welding during manufacturing of the coach. Further, the universal assembly fixture (100) includes the plurality of under frame resting pads (110) which is adapted to provide a proper resting and leveling surface to the under-frame of the coach during the manufacturing of the coach. In an embodiment, the under frame resting pad (110) is at least a swing type resting pad.
[0033] Figs. 5a and 5b depict a perspective view of lifting jack, according to embodiments as disclosed herein. The universal assembly fixture (100) further includes the plurality of lifting jacks (112) which are disposed at predetermined locations in the gap defined between the rows of the platform support pillars (102). In an embodiment, the universal assembly fixture (100) includes at least four lifting jacks (112) disposed which are configured to lift the under-frame during loading of the coach to the universal assembly fixture area and lift the coach for unloading after manufacturing the coach. In an embodiment, the lifting jacks (112) is at least electrically operated lifting jack.
[0034] Fig. 6 depicts a perspective view of a welding track arrangement and a welder, according to embodiments as disclosed herein. The universal assembly fixture (100) further includes the weld track arrangement (114) which is installed towards the upper end and the lower end of the plurality of platform support pillars (102). In an embodiment, the weld track arrangement (114) is provided such that the track is parallel to the side walls of the coach. The weld track arrangement (114) acts as a guide way for the weld device (116) to slide along the entire length (i.e. from one end to other end) of the coach of the railway vehicle. The weld device (116) is made to side in the weld track arrangement (114) while welding the side walls with the roof and the under-frame of the coach.
[0035] Figs. 7a and 7b depict a perspective view of sidewall window area clamps, according to embodiments as disclosed herein. The universal assembly fixture (100) further includes the plurality of sidewall window area clamps (124) which are configured to grip a window area of the sidewall. In an embodiment, the sidewall window area clamp (124) is at least an adjustable clamp which is adapted to support the sidewall based on the predetermined width of the sidewall. The universal assembly fixture (100) includes the second platform (126) which is disposed towards both ends of the coach to provide a required access for shifting the coach from the universal assembly fixture area to another location.
[0036] Fig. 8 depicts a perspective view of a dummy bogie of the universal assembly fixture, according to embodiments as disclosed herein. Furthermore, the universal assembly fixture (100) includes the plurality of dummy bogie (128) which is adapted to facilitate movement of the under-frame to the universal assembly fixture area and shift the coach to another location after manufacturing.
[0037] Further, the universal assembly fixture (100) includes controller (118) which is provided in communication with the first movable platform (104), the each side wall clamp (106), the plurality of sidewall and under-frame joint clamps (108), the plurality of under frame resting pads (110), the plurality of lifting jacks (112), and the welding device (116). The controller (118) is configured to actuate or operate the universal assembly fixture based on a predefined program which may be stored in a memory unit of the controller (118). The controller (118) said controller (118) is configured to operate said welding device (116), to connect the sidewalls with the roof and the under-frame by welding, thereby manufacturing the coach of said railway vehicle. The controller (118) is configured actuate clamping of the front wall, the rear wall, and the side walls using a plurality of front wall clamps, a plurality of rear wall clamps, the plurality of side wall clamps (106), the plurality of sidewall window area clamps (124), and the plurality of sidewall and under-frame joint clamps (108) for performing welding operation. Also, the universal assembly fixture (100) includes a camber removing arrangement (132) for removing a camber (or bend) in the under-frame of said coach as shown in Fig. 9.
[0038] Fig. 10 depicts a flowchart indicating a method for manufacturing a coach of a railway vehicle, according to embodiments as disclosed herein. For the purpose of this description and ease of understanding, the method (200) is explained herein below with reference to making a mainline electrical multiple unit (MEMU) coach, an electrical multiple unit (EMU) coach, a Linke Hofmann Busch (LHB) coach of the vehicle such as train. However, it is also within the scope of this invention to practice/implement the entire steps of the method (200)in a same manner or in a different manner or with omission of at least one step to the method (200) or with any addition of at least one step to the method (200) for making any other type of coaches of vehicles such as bus, metro trains, trams and any other type of transport vehicles without otherwise deterring the intended function of the method (200) as can be deduced from the description and corresponding drawings. In an embodiment, the method (200) includes, loading an under-frame of said coach on plurality of dummy bogies (128) and shifting said under-frame to a universal assembly fixture area(at step (202)). Further, the method (200) includes raising said under-frame of said coach using a plurality of lifting jacks (112) (at step (204)). Furthermore, the method (200) includes rotating a plurality of under frame resting pads (110) to a predetermined position and resting said under-frame on said under frame resting pads (110) by lowering said plurality of lifting jacks (112) (at step (206)). Additionally, the method (200) includes placing a front wall, a rear wall, two side walls of said coach at predetermined positions of said under-frame (at step (208)). Moreover, the method (200) includes clamping said front wall, said rear wall, said side walls using a plurality of front wall clamps, a plurality of rear wall clamps, a plurality of side wall clamps (106), a plurality of sidewall window area clamps (124), and plurality of sidewall and under-frame joint clamps (108) (at step (210)). Further, the method (200) includes positioning a roof of said coach on top of said front wall, said rear wall, said side walls (at step (212)). Furthermore, the method (200) includes actuating a welding device (116) by a controller (118) to connect said sidewalls with said roof and said under-frame by welding (at step (214)). Also, the method (200) includes declamping said coach from said plurality of front wall clamps, said plurality of rear wall clamps, said plurality of side wall clamps (106), said plurality of sidewall window area clamps (124), and said plurality of sidewall and under-frame joint clamps (108) (at step (216)). Finally, the method (200) includes unloading said coach on said plurality of dummy bogies (128) and shifting said coach from said universal assembly fixture area to another location (at step (218)).
[0039] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein.
,CLAIMS:We claim:
1. A universal assembly fixture (100) for manufacturing a coach of a railway vehicle, said coach including a front wall, two side walls, a rear wall, an under frame, and a roof, said universal assembly fixture (100) comprising:
a plurality of platform support pillars (102) mounted above a ground surface, said plurality of platform support pillars (102) disposed in two rows which are parallel and define a predetermined gap there between;
a first movable platform (104) disposed at an upper end of each of said corresponding platform support pillar (102);
at least one side wall clamp (106) disposed below said first movable platform (104), said side wall clamp (106) is disposed towards an interior side of each of said corresponding platform support pillar (102);
a plurality of sidewall and under-frame joint clamps (108) and a plurality of under frame resting pads (110) mounted in rows on said ground surface towards a lower end and said interior side of said plurality of platform support pillars (102);
a plurality of lifting jacks (112) mounted on said ground surface at predetermined locations;
a weld track arrangement (114) installed towards said upper end and said lower end of said plurality of platform support pillars (102);
a welding device (116) configured to move from one end to other end on corresponding said weld track arrangement (114);
a controller (118) in communication with said first movable platform (104), said each side wall clamp (106), said plurality of sidewall and under-frame joint clamps (108), said plurality of under frame resting pads (110), said plurality of lifting jacks (112), and said welding device (116); and
a power source (120) for supplying power to said universal assembly fixture,
wherein,
said controller (118) is configured to operate said welding device (116), to connect said sidewalls with said roof and said under-frame by welding, thereby manufacturing said coach of said railway vehicle.
2. The universal assembly fixture (100) as claimed in claim 1, wherein each of said plurality of platform support pillars (102) includes a first pillar (102a) disposed towards an exterior side of said plurality of platform support pillars (102), a second pillar (102b) disposed towards said interior side of said plurality of platform support pillars (102), a connecting member (102c) connecting said first pillar (102a) and said second pillar (102b) and at least one sliding track (102s) defined at said upper end of said platform support pillar (102).
3. The universal assembly fixture as claimed in claim 1, wherein said first movable platform (104) is mounted on said sliding track (102s) defined at said upper end of said platform support pillar (102), said movable platform (104) is configured to move from a distal end to a proximal end and vice-versa, by sliding within a predetermined distance defined by said sliding track (102s).
4. The universal assembly fixture as claimed in claim 3, wherein each of said first movable platform (104) is connected with an actuating means (104a) to move said movable platform (104) from said distal end to said proximal end and vice-versa, said actuating means (104a) is actuated by said controller (118) based on said width of said coach, said actuating means (104a) is at least a hydraulic actuator.
5. The universal assembly fixture as claimed in claim 4, wherein said first movable platform (104) is connected to said weld track arrangement (114) at one side and a side railing (130) on the other side, said side railing (130) is installed in said first movable platform (104) to provide safety to an operator.
6. The universal assembly fixture as claimed in claim 3, wherein each of said first movable platform (104) includes a changeover stopper (122) to accommodate a predetermined width of said railway vehicle within said gap defined between said rows of plurality of platform support pillars (102).
7. The universal assembly fixture as claimed in claim 1, wherein each of said side wall clamp (106) is connected to said first movable platform (104) such that a clamping face (106a) of said side wall clamp (106) is disposed towards said gap defined between said plurality of platform support pillars (102), said side wall clamp (106) is adapted to facilitate gauging (coach width) and holding sidewall of said coach, said side wall clamp (106) is connected to said actuating means (104a), said actuating means (104a) is configured to move said slide wall clamp (106) between a unclamping position to a clamping position and vice-versa.
8. The universal assembly fixture as claimed in claim 1, wherein said plurality of sidewall and under-frame joint clamps (108) is adapted to hold said side wall and said under-frame in a predetermined position for welding during manufacturing of said coach.
9. The universal assembly fixture as claimed in claim 1, wherein said plurality of under frame resting pads (110) is adapted to provide a proper resting and leveling surface to said underframe of said coach during said manufacturing, said under frame resting pad (110) is at least a swing type resting pad.
10. The universal assembly fixture as claimed in claim 1, wherein said plurality of lifting jacks (112) includes at least four lifting jacks (112) disposed within said gap defined between said plurality of platform support pillars at predetermined locations to lift said under-frame during loading of said coach to said universal assembly fixture area and lift said coach for unloading after manufacturing, said lifting jacks (112) is at least electrically operated lifting jack.
11. The universal assembly fixture as claimed in claim 1, wherein said universal assembly fixture (100) includes a plurality of sidewall window area clamps (124) to grip a window area of said sidewall, said sidewall window area clamp (124) is at least an adjustable clamp which is adapted to support said sidewall based on said predetermined width of said sidewall.
12. The universal assembly fixture as claimed in claim 1, wherein said universal assembly fixture (100) includes a second platform (126) disposed towards both ends of said coach to provide a required access for shifting said coach from said universal assembly fixture area to another location.
13. The universal assembly fixture as claimed in claim 1, wherein said universal assembly fixture (100) includes a plurality of dummy bogie (128) to facilitate movement of said under-frame to said universal assembly fixture area and shift said coach to another location after manufacturing.
14. The universal assembly fixture as claimed in claim 1, wherein said universal assembly fixture (100) includes camber removing arrangement (132) for removing a camber (or bend) in said under-frame of said coach.
15. The universal assembly fixture as claimed in claim 1, wherein said universal assembly fixture (100) includes a plurality of front wall clamps and a plurality of rear wall clamps which are configured to hold said front wall and said rear wall at a predetermined position during manufacturing of said coach.
16. A method (200) for manufacturing a coach of a railway vehicle using a universal assembly fixture (100), said method comprising:
loading an under-frame of said coach on plurality of dummy bogies (128) and shifting said under-frame to a universal assembly fixture area;
raising said under-frame of said coach using a plurality of lifting jacks (112);
rotating a plurality of under frame resting pads (110) to a predetermined position and resting said under-frame on said under frame resting pads (110) by lowering said plurality of lifting jacks (112);
placing a front wall, a rear wall, two side walls of said coach at predetermined positions of said under-frame;
clamping said front wall, said rear wall, said side walls using a plurality of front wall clamps, a plurality of rear wall clamps, a plurality of side wall clamps (106), a plurality of sidewall window area clamps (124), and plurality of sidewall and under-frame joint clamps (108);
positioning a roof of said coach on top of said front wall, said rear wall, said side walls;
actuating a welding device (116) by a controller (118) to connect said sidewalls with said roof and said under-frame by welding;
declamping said coach from said plurality of front wall clamps, said plurality of rear wall clamps, said plurality of side wall clamps (106), said plurality of sidewall window area clamps (124), and said plurality of sidewall and under-frame joint clamps (108); and
unloading said coach on said plurality of dummy bogies (128) and shifting said coach from said universal assembly fixture area to another location.