Hitachi Rail develops a PRM-TSI compliant, lightweight aluminium storage unit for bicycles

Working in close cooperation with its design and production partners, Hitachi Rail has developed a PRM-TSI compliant, lightweight storage unit for bicycles for its new class 800/801 series train.

According to TRB Lightweight Structures (TRB), these new Hitachi Class 800/801 trains will be replacing existing high speed trains in the UK as part of the latest Intercity Express Programme (IEP). The original concept for the new class 800/801 series train was to design spacious new passenger carriage interiors, including convenient bike storage facilities. It explains that, right at this early concept stage, Hitachi also brought in Lyndon Newman, Engineering Director of TRB and his team. The role of TRB was to evaluate the design and provide a cost effective method of manufacturing the bike storage unit to meet all technical specifications and rail standards, and to comply with PRM (persons of reduced mobility) passenger needs.

To minimise weight and maximise space, aluminium honeycomb sandwich panels were specified for the walls, the sliding and folding door sections, and for the ceiling. The type of sandwich panels used are fabricated using an aluminium honeycomb core with inner and outer aluminium skins, bonded together with a high strength modified epoxy adhesive film, then finished by spray painting using a water based paint system. Aluminium honeycomb sandwich panels have been successfully used by TRB in other rail applications, such as partitions and headers, where a lightweight, strong and durable structure is needed in minimal space. For the sliding door and gangway panels, a high pressure laminate is specified. The same door system is also specified for the catering units, also being supplied by TRB.

Flat sandwich panels are fabricated on a platen press, with the curved door sections being produced using a custom made tool, moulding the aluminium core and skins together using a lay-up and vacuum bagging process in an oven. A number of painted fibre reinforced plastic (FRP) components are also fabricated for the bike units.

TRB says the validation process carried out for this project included extensive in-house component performance testing. Accelerated cyclic testing (equivalent to seven years of use without failure or breakdown) were conducted on all critical moving components, such as the sliding door mechanism, door handles and latches using proprietary equipment and software developed by TRB engineers. Impact, load bearing strength and other mechanical property tests were also carried out.

The Fire, smoke and toxicity (FST) testing was carried out by Exova Warrington Fire using TRB manufactured components, including painted aluminium honeycomb panels and painted FRP panels. The new class 800/ 801 series Hitachi trains are specified to meet BS 6853:1999-Category 1b.

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