WCR Bogie Information Issue 1 - · PDF fileTitle: WCR Bogie Information Issue 1 -...

Bogie Information

Issue 1

Copyright © 2017 William Cook Rail WCR Bogie Information

William Cook Rail Bogie Information

Issue 1: 16 March 2017

Copyright © 2014-2017 William Cook Rail Ltd. All rights reserved.

This document is protected by copyright and design right owned by William Cook Rail Limited. All rights conferred by the law of copyright conventions are reserved to the copyright owner.

No part of this document may be used, disclosed, transmitted, copied, lent, sold, stored in any retrieval system of any nature or otherwise reproduced or circulated (in any form or by any means including electronically and whether or not transiently) without the express prior written consent of the copyright owner.

General Contact Information:

William Cook Rail Ltd Cross Green Leeds LS9 0DX England Tel. +44 (0) 113 249 6363 Web: www.william-cook.co.uk/rail.html Email: [email protected]

For information about our company, please visit our website.

http://www.william-cook.co.uk/rail.html

mailto:[email protected]

Copyright © 2017 William Cook Rail Page 1 of 29 WCR Bogie Information

IN-HOUSE CAPABILITIES

• Design and Development

• CAD Modelling

• Solidification Simulation

• CNC Patternmaking

• 3D Rapid Prototyping

• Casting and Fabrication

• Stress-Relieving, Air and Inert Atmosphere Normalising, Tempering and Quenching

• Hot Wash De-Greasing, Shot and Sand Blasting

• Magnetic Particle, Ultrasonic and Radiographic Inspection

• Finite Element Analysis

• Fatigue Testing and Non-Destructive Testing

• Collision Damage Repairs, Fault Finding and Clash Testing

• Tooling Manufacture

• Machining

• CMM Metrology

• Laser Scanning

• Fabrication by qualified welders using the latest MIG and TIG welding equipment

• Dipping, Hand Painting, Spray Painting, Heated Drying


PRO-ENGINEER DESIGN SOFTWARE


MAGMASOFT


CNC PATTERNMAKING


IN-HOUSE MACHINING

Correa HVM-50-MG Travelling Column Milling Machine

Correa FOX-50: Machining Bogie Frames


CMM METROLOGY


ACCREDITATIONS AND APPROVALS

• ISO 9001:2008 Quality Management System Standard

Certificate number: 10008591

• ISO 14001:2004 Environmental Management System Standard

Certificate number: LRQ 4003564/B

• BS OHSAS 18001:2007 Occupational Health & Safety Management System

Certificate number: LRQ 4005915/B

• EN 15085-2, Certification Level CL1

Certificate number: TÜVNORD/15085/CL1/167/0A4/13

• Deutsche Bahn

Certificate number: 3342017

• IRIS


CUSTOMERS


SERIES 3 ELECTROSTAR BOGIE FRAME


ELECTROSTAR FRAME END


ELECTROSTAR FRAME END WITHOUT DAMPER BRACKET


ELECTROSTAR TRAILER TRANSOM


ELECTROSTAR CENTRE SECTION


ELECTROSTAR BOGIE FRAME COMPLETE WITH AXLES BOXES AND BRAKE HANGERS


METRO LOS TEQUES BOLSTER


CONVERSION OF FABRICATION TO MACHINED CASTING

ALSTOM Metro Los Teques Bolster

Original diagram of fabricated plate bolster (highlighted in yellow).

Developed from fabricated component to 3 piece cast steel assembly,

pre-machined by William Cook ready for welding and final machining.



ALSTOM Metro Los Teques Bolster

The 3 piece pre-machined assembly ready for welding.

The 3 piece welded assembly at Alstom.

The 3 piece finished assembly at Alstom. The 3 piece welded assembly in position on the train.

Copyright © 2017 William Cook Rail Page 18 of 29 WCR Coupler Information

STADLER - END BEAM


CONVERSION OF FABRICATION TO MACHINED CASTING STADLER End Beam

Existing fabricated design showing three separate

components.

One piece casting design. One piece casting, fully machined.

Magmasoft Validation and Simulation

• Predicts potential internal defects.

• Predicts potential contraction and distortion.

CNC Patternmaking

Finished Product



ALSTOM Suspension Pot

CAD Model

Finished Machined Casting


DEVELOPED FROM PRIMARY CONCEPT AS SUGGESTED BY BOMBARDIER

Initial design by Bombardier CAD Modelled by William Cook

William Cook Magmasoft Simulation Un-machined Casting

Finished Machined Casting


PRODUCT DEVELOPMENT BOMBARDIER Flexx Eco Frame

Casting Design Proposal - Bogie Frame

7 piece cast steel frame with cast or forged ends

Side Frame – outer view



Casting Design Proposal - Bogie Frame

Flexx Eco Cast Transom

7 piece Frame, pre-machined and ready for fabrication



Hybrid Proposal: Cast Sideframe, Fabricated Transom

Motor Frame Assembly, complete (top)

• Existing, Fabricated, Crossrail, Motor Frame.

• Spring Pots and Fabricated Transom to be retained.

• Minor Brackets and Fittings to be welded on.



Hybrid Proposal: Cast Sideframe, Fabricated Transom

Full Assembly



Gearbox Bracket Detail

Gearbox Bracket


BOMBARDIER TRANSPORTATION Crossrail, Gearbox Bracket

Gearbox Bracket


STADLER – AXLEBOX BODY


FINANCIAL INFORMATION 2015/2016

• Group Sales: £50 Million

• Group Net Assets: £58 Million

• Employees: 450

Date post:	08-Mar-2018
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