Javier Fernández Aguirrebeña – Project Management Composites
15th September 2022
At Aernnova we already had background in the railway sector. Both with engineering work and the manufacture of panels and components for different trams and trains. For example, the modernization of the interior design of the blue line of the Sao Paulo metro, several exterior roof and front fairings of the Madrid metro, window and door fairings of the driver’s compartment in Renfe trains, the interior panels of the Talgo high-speed trains for the Haramain project and others.
In 2016 Talgo, the leading manufacturer of high-speed trains, was awarded with the contract corresponding to the tender by Renfe for the supply of 30 high speed train-sets. Talgo won the tender with its new-generation AVRIL train, which boasts a maximum speed of 330 km/h, energy efficiency, the possibility of operating in France and in different gauges lines, and a passenger capacity far superior to that of any other competitor.
Because the new Talgo train-sets, which have 2 power heads and 12 articulated cars, have a capacity for 581 passengers in the high-occupancy configuration or 507 passengers in the compositions that include 1 cafeteria car. And how is it possible to fit considerably more passengers on the same train than competitors without having a double-deck configuration? This is one of Talgo’s greatest assets; in tourist class cars, instead of 4 seats per row (2+2) there will be 5 seats per row (3+2). With the same seat width and the same distance between seats. And also with maximum accessibility because the floor of the train is at the same level as the platform.
Talgo has the word “Light” in its name. Talgo is able to manufacture the lightest passenger rolling stock in the world. And at Aernnova we have it in our DNA to develop and manufacture lightweight structures, optimizing weight and meeting all other requirements.
For this reason, Talgo has assigned Aernnova the design and manufacture of the interiors and front panels in lightweight materials. This is the first project in which Talgo subcontracts the design and manufacture of these 2 complete packages.
Front Nose Assembly Sevilla:
Front Nose Molding:
For the interior design, the new – and critical – weight saving requirement was added to a long list of usual requirements; they must withstand high Fire and Smoke standards (EN-45545-2), be very quiet (acoustics), with modular panels that have to be assembled and disassembled in less than 20 minutes, deflection and impact resistant, meet vibration requirements, withstand temperatures of -30ºC and +45ºC (environmental), plus other finishing requirements (anti-graffiti, anti-scratch, etc.).
Talgo and Aernnova jointly worked to maximize the efficiency, flexibility, versatility, accessibility and due to extremely light weight, cleanliness and sustainability of the train-sets.
Window Fairing Assembly Toledo:
Window Fairing Toledo:
Similarly, the front of the train (front nose and cabin roof) also needs to withstand significant loads generated at very high speeds (during certification tests, the train reached 363km/h) while ensuring minimum weight. New oven-cured CFRP materials are innovated.
It is a major challenge in which 2 engineering teams (Miñano and Madrid) and 2 manufacturing teams (Toledo and Seville) are working together with our client Talgo teams. Railway projects, unlike aeronautical projects, concentrate all their manufacturing in 2 or 3 years, so industrialization and manufacturing are carried out at a particularly high rate; for example, every day all the kits needed for the interior of a car have been manufactured.
In the case of interior design, 3,391 kits have been manufactured and delivered in 2.5 years, amounting to more than 47,000 panels. And 66 front panels (roof and nose) have been manufactured and delivered in a first phase with another 26 planned for the coming months for another series of compositions that will use the same powerheads as the AVRIL.
So as soon as the commercial service of the “AVRIL” trains begins in the coming months, both from the outside and when entering a car, we will be able to look up and down at all the details and smile with a satisfied face at the great work that has been done.
