DIN 6701-2 -2006 英文版.doc

Type text May 2006DIN 6701-2DINICS 45.040; 83.180Use of adhesive bonding in the manufacture of rail vehicles and parts of rail vehiclesPart 2: Qualification of user-companies, quality assuranceTotal number of pages: 29 Railway vehicle standard committee at the DIN (Deutsches Institut fr Normung e.V.) 27Type textType text DIN 6701-2:2006-05Table of contentsForewordThis standard was developed from NA 087 05-06 AA “Adhesive Bonding Technology in Rail Vehicle Construction” of the Railway Vehicle Standards Committee (FSF).Adhesive bonding is a key process in the manufacture of rail vehicles and parts of rail vehicles. The standards in the DIN 6701 series specify the requirements for “adhesive bonding”, a so-called special process. These requirements are based on the technical standards for adhesive bonding, taking into account the special needs for rail vehicle construction.The standards in the DIN 6701 series “Use of adhesive bonding in the manufacture of rail vehicles and parts of rail vehicles” comprise:- Part 1: Basic terms and basic regulations- Part 2: Qualification of adhesive users (hereafter called user-companies) and compliance evaluation - Part 3: Design specifications (in preparation)- Part 4: Regulations for manufacturing adhesive bonds and quality assurance (in preparation)1Area of applicationThis standard applies for bonding and sealing substrates for manufacturing and repairing rail vehicles and parts of rail vehicles. It defines the general terms and basic regulations for bonding and sealing work. It:- assigns parts to classes- defines the requirements placed on user-companies- describes the procedure for accrediting user-companies and- describes the procedure for compliance evaluation.2Reference standardsThe following documents are required for using this standard. Where date versions are mentioned, only these are relevant. Where date versions are not mentioned, the most recent version of the document applies (including all amendments).DIN EN ISO/IEC 17025, General requirements for the expertise of testing and calibration laboratoriesGuideline DVS-EWF 3301, European Adhesive Specialist1)Guideline DVS-EWF 3305, European Adhesive Bonder1)Guideline DVS-EWF 3309, DVS-EWF training course - European Adhesive Engineer - EAE1)Guideline DVS 3310, Quality requirements in adhesive bonding technology1)1) Available from Beuth Verlag GmbH, 10772 Berlin, Germany3TermsThe following terms are used in this document, in accordance with DIN 6701-1.3.1Classification of bonded jointsTable 1 classifies bonded joints on rail vehicles and on components and parts of rail vehicles as a function of the relevant safety requirements.The classification of the bonded parts into part classes is based on the potential effect of failure of the bonded joint as stated by the relevant design companies/engineers. The same applies for repairs to bonded joints and for repairs realized by adhesive bonding. The part classes must be indicated on drawings. The relevant design engineer must involve the supervisor in charge of the bonding work (SIC) in the process of assigning bonded parts to classes. Table 1 Classification of bonded jointsClassDescriptionExamples a A1Bonded joints on rail vehicles and parts of rail vehicles with high safety requirements - GFRP head to shell- front window in front panel- side windows in carriage body- plating on carriage structure- external parts, equipment boxes on carriages- roof structures A2Bonded joints on rail vehicles and parts of rail vehicles with average safety requirements- interior furnishings e.g. wall cabinets, partition walls, panelling- floor coverings to floor base - tanks not under pressure- seat attachment to floor A3Bonded joints on rail vehicles and parts of rail vehicles with low safety requirements- plates- mirrors- floor coverings- handles- ventilation grillesA4This class applies to companies which has no own production of bonded parts but which- designs or- purchases and sells on or- purchases and fitsbonded parts assigned to classes A1 and A2.a Besides the above-mentioned examples, other bonded joints on rail vehicles can also be assigned to the above classes depending on their safety requirements. The classification must be agreed in a written contract between the customer and the user-company. The requirements of the relevant official body must be heeded. 4Requirements on user-companies4.1Quality requirements on user-companiesUser-companies must meet the quality requirements set down in guideline DVS 3310. In addition, sections 5.3 to 5.7 apply for part classes A1 to A3 and sections 4.2.1, and 5.6 apply for part class A4.4.2Workforce training4.2.1GeneralDepending on the class of bonded joint, the user-company must possess adequately trained employees to carry out and supervise the bonding work and test the resulting bonded joints.The degree of training required to meet the quality obligations depends on the specific classification of the rail vehicles and rail vehicle parts. Safety considerations demand that suitably trained employees can guarantee the appropriate quality assurance. The qualifications mentioned in the standard for example purposes are a guideline for the degree of training that is required. In individual cases the actual level of knowledge required of specific areas may be greater or less. With regard to the former, additional training may be required. With regard to the latter scenario, special training courses geared to specific rail vehicle parts may prove unnecessary, meaning they can be omitted. Deviations from the levels of training mentioned herein for example purposes must be reasoned in each individual case.4.2.2Technical knowledgeEmployees who are assigned adhesive bonding tasks must have the necessary expertise to carry out the work. It must be demonstrated that they possess the relevant technical knowledge.The user-company defines what manufacturing experience, training and technical knowledge are required. That depends on the particular tasks that have been assigned and the responsibility. All documents relating to qualifications must be kept up to date.Employees involved in adhesive bonding workEmployees who are involved in adhesive bonding work should normally be assigned to one of the following groups. This depends on the nature and/or complexity of the production process.Table 2 Qualifications of employees and adhesive bonding tasksLevelQualifications(see Annex D)Educational backgroundWork areaEmployees supervising adhesive bonding work1Comprehensive technical knowledge, for example:- EAE in accordance with EWF guidelinea 517-01- DVS-EWF-EAE in accordance with DVS-EWF 3309- Equivalent qualificationbCompleted course in one of the natural or engineering sciences at a technical college or university. Additionally, a successfully completed course at an accredited training establishment. Employees supervising the adhesive bonding work and equally qualified deputies for all part classes. Includes Levels 2 and 3.2Specific technical knowledge, for example:- EAS in accordance with EWF guidelinea 516-01- DVS-EWF-EAS in accordance with DVS-EWF 3301- Equivalent qualificationcTechnologist or specialist training at an accredited training establishment. Employees supervising the adhesive bonding work for part class A2 and non equally qualified deputies for part class A1 (see Table 3). Includes Level 3. Employees carrying out practical adhesive bonding work3Technical knowledge, for example:- EAB in accordance with EWF guidelinea 515-01- DVS-EWF-EAB in accordance with DVS-EWF 3305- Equivalent qualificationdCourse at an accredited training establishment.Employees carrying out the practical adhesive bonding work independently and effectively following work instructions. aCertificates for employee qualifications must be issued by a body officially accredited in accordance with DIN EN ISO/IEC 17025.bEquivalent qualification: proof of comprehensive technical knowledge and proof of several years experience.cEquivalent qualification: proof of specific technical knowledge and proof of several years experience.dEquivalent qualification: proof of technical knowledge and proof of several years experience. Comprehensive technical knowledgeEmployees supervising the adhesive bonding work who possess comprehensive technical knowledge for the planning, execution, supervising and inspecting of all the tasks and who are responsible for the adhesive bonding production process.Specific technical knowledgeEmployees supervising the adhesive bonding work whose technical knowledge for the planning, execution, supervising and inspecting of tasks and whose responsibility are within a specific or limited area.Technical knowledgeEmployees carrying out practical tasks who possess the knowledge required to independently and effectively carry out adhesive bonding work following work instructions.4.2.3Employees carrying out the practical adhesive bonding workAll the employees carrying out practical tasks including operators of bonding robots and automated production units must possess suitable qualifications. For part classes A1 to A3, the minimum required qualification is Level Employees supervising the adhesive bonding workThe user-company must have suitably qualified personnel (for supervising the adhesive bonding work) analogous to directive DVS 3310, so that the employees carrying out the practical adhesive bonding work can fulfil the assigned tasks. These tasks are responsibilities are defined in Table 3. Such persons, who are also responsible for the quality assurance tasks, must possess adequate authority in order to be able to give orders for all necessary measures. The obligations, interrelationships and limits of the area of responsibility of such persons must be defined.Qualifications of employees supervising the adhesive bonding workSee Table .2Tasks and responsibilities.For tasks and responsibilities see Table 3.Table 3 must be used as a guide for defining the quality-related tasks and the responsibilities of the employees who supervise the adhesive bonding work. There can be additional requirements for special applications. It is unnecessary for all the listed points to be used by all user-companies or for all quality systems.The responsibilities given in Table 3 can be linked to a number of tasks such as;- Precise details or preparation;- Coordination;- Monitoring;- Inspection or release. In cases where the supervising work is carried out by more than one person, the tasks and responsibilities of each person must be specified.In accordance with Annex A, the user-company must appoint at least one person to supervise the adhesive bonding work. The supervision of the adhesive bonding work is the responsibility of the user-company.For some production tasks, the tasks and responsibilities can be delegated to other parties. Tasks carried out by such delegated parties are also the ultimate responsibility of the employee in charge of supervising adhesive bonding work (SIC) in accordance with this standard (see Table 3).Table 3 Tasks and responsibilitiesNo.Part classA1A2SICDeputySIC, DeputyMinimum qualification level of the SIC (supervisor in charge of the bonding work) in accordance with Table 21221.1Inspection of the contract-Suitability of the user-company for carrying out adhesive bonding work and the assigned tasks X(X)X1.2Design tests-Compliance with relevant adhesive bonding standards, guidelines and technical information sheets-Load analysis-Design of the bonded joint to meet design requirements- Accessibility for bonding- Load bearing analysis of the bonded joint- Dimensions of the bonded jointXXXXXXX(X)-(X)(X)(X)XXXXXX1.3Testing the specifications of the bonded joint in accordance with DIN 6701-3 X(X)X1.4Substrate material / adhesive selection and testingX(X)X1.4.1Substrate material-Suitability for bonding-Selection of the surface pretreatment method-Any additional requirements for supplying the substrate materials- Labelling, storage and handling of the substrate materials- TraceabilityXXXXX(X)(X)(X)XXXXXXXTable 3 (continued)No.Part classA1A2SICDeputySIC, Deputy1.4.2Adhesives-Qualification of the adhesives-Supply conditions-Any additional requirements for supplying the adhesives, including the type of certificates for the adhesives-Labelling, storage and handling of the adhesives XXXX(X)XXXXXXX1.5Suitability of sub-suppliers-Suitability of sub-suppliers: qualifications, technical facilities, workforce expertise and production facilitiesX(X)X1.6Production planning and testing-Drawings and parts lists, specification of the materials, auxiliary materials and equipment-Work and repair instructions, their suitability and validation via checks-Bonding and fixing devices-Suitability and validity of the qualifications of the employees involved in the adhesive bonding work-Bonding and assembly procedures for the part (bonding plan)-Test requirements for the bonded joints in the production-Requirements for testing bonded joints-Ambient conditions XXXXXXXXX(X)(X)(X)(X)(X)(X)(X)(X)(X)XXXXXXXXX1.7Equipment checks-Suitability of bonding devices-Suitability of the production conditions-Preparation, labelling and handling of auxiliary materials and equipmentXXXTable 3 (continued)No.Part classA1A2SICDeputySIC, Deputy1.8Specification of the work processes involving adhesive bonding-Preparatory tasks-Adhesive bonding tasksXXX1.9Qualification of the process -Suitability of machinery-Suitability of the processXXX1.10Testing the bonded joints-Visible inspection-Destructive and non-destructive testsXXX1.11Appraisal of seams and seals X(X)X1.12Documentation-Preparation and storage of the necessary reports including the reports of delegated partiesXXXLegend:X:unlimited authority(X):limited authority, following the instructions of the SIC- :no authorityUser-company and number of SICsDepending on the scope of the adhesive bonding work, the user-company must have a sufficient number of trained personnel, qualified in accordance with the EWF code , for planning, execution and monitoring in accordance with the prescribed requirements. If there is no qualification in accordance with the EWF code, the user-company must demonstrate that the supervisory personnel for the area of validity of this standard have equivalent technical knowledge. The area of validity of this standard covers Levels 1 and 2 as described in Table .4Authority of SICs within user-companySupervisors in charge are persons must be able to carry out their tasks and responsibilities in accordance with this standard in an unrestricted way. For this they must possess the relevant authority to issue orders and decision-making authority independent of production necessities.Only authorised deputies having equal or higher qualifications may fully deputise for supervisors in charge.Company owners, managing directors, managers and production managers can only be authorised as supervisors in charge for part class A1 if their company operations involve little adhesive bonding. The appointment of such persons as a deputy for the supervisor in charge is possible in all cases.External supervisory personnelIn special cases, SICs not employed by the user-company may act as the SIC for part classes A1, A2 and A4 if the following conditions are fulfilled:- The user-company employs and authorises a deputy in accordance with Annex A (not for part class 4);- The SIC is contracted to the user-company. The approval of the primary employer must be given;- The work time involved is laid down in a contract and can be clearly demonstrated;- The external SIC can only be authorised for one user-company. Exception: For repair work at user-companies where operations involve little adhesive bonding, it is permissible for an SIC to be responsible for several user-companies. The decision about this rests with the certification body.4.2.5Personnel for monitoring and testingThe user-company must possess a sufficient number of suitably qualified personnel for planning and carrying out monitoring activities, quality tests and inspection of the adhesive bonding operations in accordance with the prescribed requirements. The evaluation of the results is carried out by the SIC at the company.4.3Technical equipment4.3.1General requirementsThe following equipment and facilities, provided they are needed, must be available:- Defined workplaces for adhesive bonding work (see work instructions, repair instructions);- Equipment for surface preparation, e.g. disposable cloths, cleaning agents, tools for passivating and deburring surfaces;- Auxiliary equipment for dosing, e.g. balances;- Equipment for surface pretreatment, e.g. grinding machines, grit blasting equipment;- Equ