A highly integrated roof assembly for rail transit vehicles

Abstract

This application discloses a highly integrated roof assembly for rail transit vehicles, relating to the technical field of rail transit vehicle components. It includes a main roof structure composed of an upper panel, a lower panel, and a core layer. A load-bearing frame is integrated with the main roof structure to support and transfer loads to the vehicle body. Air ducts and cable trays are located inside the main roof structure for ventilation and electrical wiring harness arrangement, respectively. A mounting frame is located on top of the main roof structure, with several mounting interfaces for installing air conditioning units and power battery modules. Additionally, components such as heat dissipation plates are provided to assist in heat dissipation. This application achieves a high degree of functional integration. Through a rational structural design, it integrates multiple roof functions while ensuring good ventilation and heat dissipation performance, making the roof structure more stable and reliable.

Description

Technical Field

[0001] This application relates to the technical field of rail transit vehicle components, and in particular to a highly integrated rail transit vehicle roof assembly. Background Technology

[0002] In the field of vehicle engineering technology, the development of rail transit vehicles is progressing rapidly. Improvements in their performance and functionality are crucial for enhancing transportation efficiency, ensuring passenger safety, and improving the riding experience. As a vital component of the vehicle, the roof's performance and functionality directly impact the overall performance of the vehicle. With the continuous development of rail transit, the functional requirements for the roof are becoming increasingly stringent. It not only needs to provide basic structural support and protection but also integrates more functions to meet the operational needs of the vehicle.

[0003] Traditional vehicle roofs primarily function as coverings, providing structural support and protection from the external environment. Various devices installed on the roof, such as air conditioners, power batteries, and sensor covers, are typically treated as independent components, fixed to the roof or vehicle frame through later installation processes. Simultaneously, achieving functions like ventilation, wiring, sound insulation, and heat insulation also relies on adding additional ducts, wiring harnesses, sound insulation materials, and heat insulation layers—all independent components. While this approach meets basic functional requirements, it presents numerous inconveniences in practical applications. Firstly, the installation of independent components and the addition of extra parts increase the weight and complexity of the roof, hindering lightweight vehicle design and reducing handling stability and safety. Secondly, the multi-process, multi-station, decentralized assembly method leads to low production efficiency and increased manufacturing costs. Summary of the Invention

[0004] To address the problems existing in the prior art, this application provides a highly integrated roof assembly for rail transit vehicles.

[0005] This application provides a highly integrated roof assembly for rail transit vehicles, employing the following technical solution:

[0006] A highly integrated roof assembly for rail transit vehicles includes a main roof structure; a load-bearing frame, integrally formed with the main roof structure and used to install and fix the main roof structure to the vehicle body, the load-bearing frame directly bearing the overall load of the main roof structure and transferring the load to the side walls and end walls of the vehicle body; an air duct, disposed inside the main roof structure for ventilation; a cable tray, disposed inside the main roof structure for arranging electrical wiring harnesses; and a mounting frame, disposed on the top of the main roof structure, the mounting frame having several mounting interfaces for mounting air conditioning units and power battery modules.

[0007] Optionally, the main structure of the roof includes an upper panel, a lower panel, and an intermediate core layer disposed between the upper panel and the lower panel, wherein the intermediate core layer is bonded and fixed to the upper panel and the lower panel respectively.

[0008] Optionally, the load-bearing frame includes side beams disposed on both sides of the main structure of the roof, and several cross beams fixedly disposed between the side beams. Each cross beam passes through the upper panel and the lower panel and is fixedly connected to the upper panel and the lower panel respectively. The side beams are used to be installed and fixed on the vehicle body.

[0009] Optionally, the side beam is Z-shaped, and a support plate is fixedly provided at the bottom of the side beam. The edge of the lower panel overlaps the support plate, and the edge of the upper panel overlaps the side beam.

[0010] Optionally, a first groove is provided on the edges of both sides of the lower panel, the first groove is adapted to the support plate, and the lower panel overlaps the support plate through the first groove. A second groove is provided at the top of the side beam, the second groove is adapted to the upper panel, and the edge of the upper panel is located in the second groove.

[0011] Optionally, a sealing gasket is provided in both the first and second grooves.

[0012] Optionally, the air duct is arranged along the length of the main structure of the roof and is located between the upper panel and the lower panel. The upper panel is provided with a first ventilation opening that communicates with the air duct, and the lower panel is provided with a second ventilation opening that communicates with the air duct.

[0013] Optionally, a heat dissipation plate is also provided at the top of the upper panel. The heat dissipation plate is used to abut against the power battery module. An airflow channel is provided inside the heat dissipation plate. The first vent is also connected to an air supply duct. The air supply duct is connected to the airflow channel. The airflow channel is also connected to an exhaust duct. The exhaust duct is used to connect to the vehicle's exhaust system.

[0014] Optionally, the first vent is also equipped with an air supply device to guide airflow into the air supply duct.

[0015] Optionally, the cable channel is integrally formed with the upper panel by concave pressing. The upper panel is also provided with a top cover plate, which is adapted to the cable channel and fixed to the upper panel by bolts to seal the cable channel. The top cover plate is provided with a cable passage opening.

[0016] In summary, this application includes at least one of the following beneficial technical effects:

[0017] 1. The roof assembly of this application achieves a high degree of functional integration, reduces independent parts and additional components, reduces weight, and improves production efficiency; the load-bearing frame can effectively transfer the overall load of the main roof structure to the side walls and end walls of the vehicle body, avoid stress concentration, enhance the load-bearing capacity of the roof, and ensure the stability of the connection between the roof and the vehicle body; the air duct meets the ventilation needs of the vehicle, eliminating the need for additional ventilation ducts, which helps to reduce the weight of the roof assembly, lower the center of gravity of the vehicle, and improve handling stability and safety; the cable tray facilitates the arrangement of electrical wiring harnesses; and the mounting frame facilitates the installation of air conditioning units and power battery modules.

[0018] 2. This application, by inserting the crossbeams of the load-bearing frame between the upper and lower panels of the roof main structure (composed of an upper panel, lower panel, and intermediate core layer) and fixing them to both, and with the side beams installed and fixed to the vehicle body, allows the load-bearing frame and the roof main structure to be stably integrated, forming a continuous force flow path. This effectively transfers the overall load of the roof main structure to the side and end walls of the vehicle body, avoiding stress concentration, enhancing the roof's load-bearing capacity, and ensuring the stability of the connection between the roof and the vehicle body, thereby improving the overall performance of the roof assembly. Furthermore, the "Z"-shaped side beam design better adapts to the connection between the roof and the vehicle body, increasing structural stability, optimizing the structure of the load-bearing frame, and more efficiently transferring the overall roof load to the side and end walls of the vehicle body, while providing stable support for the roof main structure, contributing to improved overall strength and reliability of the roof assembly.

[0019] 3. This application provides a heat dissipation plate at the top of the roof panel, which is then placed against the power battery module. Cool air is delivered to the airflow channel within the heat dissipation plate via a ventilation system and ductwork. The heat dissipation plate then exchanges heat with the power battery module, effectively cooling the power battery module and further improving the ventilation and thermal management functions of the roof assembly. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of an embodiment of this application;

[0021] Figure 2 This is a cross-sectional view of the overall structure of an embodiment of this application, mainly used to express the specific structure of the main body of the roof;

[0022] Figure 3 This is a partial structural cross-sectional view of an embodiment of this application, mainly used to illustrate the specific structure of the load-bearing skeleton;

[0023] Figure 4 This is a schematic diagram of the overall structure of an embodiment of this application, mainly used to illustrate the internal structure of the first vent.

[0024] Figure 5 This is a schematic diagram illustrating the structure of the heat dissipation plate in an embodiment of this application.

[0025] Explanation of reference numerals in the attached drawings: 1. Main structure of the roof; 11. Upper panel; 111. First vent; 112. Air supply duct; 113. Air diversion and supply equipment; 12. Lower panel; 121. Second vent; 13. Intermediate core layer; 2. Load-bearing frame; 21. Side beam; 211. Support plate; 212. First groove; 213. Second groove; 22. Crossbeam; 3. Air duct; 4. Cable tray; 5. Mounting frame; 6. Top cover; 61. Cable outlet; 7. Heat dissipation plate; 71. Airflow channel; 72. Exhaust duct. Detailed Implementation

[0026] The following will be combined with the appendix Figure 1 - Appendix Figure 5 The technical solutions in the embodiments of the present invention are clearly and completely described herein. The described embodiments are only possible technical implementations of the present invention and not all possible implementations. Those skilled in the art can obtain other embodiments in conjunction with the embodiments of the present invention without creative effort, and these embodiments are also within the protection scope of the present invention.

[0027] This application mainly adopts a multi-functional structure integrated into the roof to achieve a high degree of integration, thereby reducing the weight of the roof, improving production efficiency, reducing costs, and enhancing the vehicle's handling stability and safety. The following is a further detailed description of this application.

[0028] This application discloses a highly integrated roof assembly for rail transit vehicles. (Refer to...) Figure 1 The roof assembly comprises a main roof structure 1, a load-bearing frame 2, an air duct 3, a cable tray 4, and a mounting frame 5. The load-bearing frame 2 is integrated with the main roof structure 1, securing it to the vehicle body and allowing it to directly bear the overall load of the main roof structure 1, transferring the load to the side and end walls of the vehicle body. The air duct 3 is located inside the main roof structure 1 for ventilation. The cable tray 4 is located inside the main roof structure 1 for arranging electrical wiring harnesses. The mounting frame 5 is located on top of the main roof structure 1 and has several mounting interfaces for installing the air conditioning unit and power battery module. This structural layout achieves a high degree of functional integration in the roof assembly, reducing independent components and additional parts, lightening the roof's weight, improving production efficiency, and also contributing to enhanced vehicle handling stability and safety. Because of the functional integration, the roof structure is more compact, reducing the weight increase and installation complexity caused by dispersed components, lowering the vehicle's overall center of gravity, making it more responsive, and the integrated design also reduces installation procedures and time.

[0029] Reference Figure 2Specifically, the main roof structure 1 includes an upper panel 11, a lower panel 12, and an intermediate core layer 13 disposed between the upper panel 11 and the lower panel 12. The upper panel 11 is generally made of high-strength metal sheet, such as aluminum alloy, which has good strength and corrosion resistance, resisting external impacts and corrosion. Alternatively, carbon fiber composite material can be used, as this material has a very low density, further reducing the weight of the roof. The lower panel 12 can also be made of aluminum alloy; its function is to wrap the intermediate core layer 13 together with the upper panel 11, forming a stable structure. The intermediate core layer 13 can be made of composite foam sandwich material, which is lightweight and has good sound and heat insulation properties, effectively reducing noise and temperature inside the vehicle. Alternatively, ceramic fiber reinforced polymer sandwich material can be used, which not only provides structural strength but also provides NVH control and thermal protection functions. The intermediate core layer 13 is firmly bonded to the upper panel 11 and the lower panel 12 with a special adhesive, ensuring the integrity and stability of the entire main roof structure 1. This structure, in which the upper panel 11, the middle core layer 13, and the lower panel 12 are bonded and fixed together, allows the materials and structure of the roof assembly to naturally possess sound insulation, heat insulation, and vibration damping properties, eliminating the need for additional materials such as sound insulation cotton and heat insulation pads.

[0030] Reference Figure 2 Specifically, the load-bearing frame 2 includes side beams 21 set on both sides of the main roof structure 1, and several crossbeams 22 fixed between the side beams 21. The side beams 21 can be made of high-strength metal profiles, such as I-beams or channel steel, which have excellent load-bearing capacity; or they can be made of high-strength composite materials, which can reduce weight while ensuring strength. The crossbeams 22 can be square steel beams or aluminum alloy beams. Square steel beams are sturdy and durable, while aluminum alloy beams are lighter. The two ends of the crossbeams 22 are fixed to the side beams 21 by welding or bolting. Then, each crossbeam 22 is inserted between the top panel 11 and the bottom panel 12, and is connected to the top panel 11 and the bottom panel 12 by welding or riveting, respectively. This connection method allows the load-bearing frame 2 to be firmly integrated with the main roof structure 1, forming a continuous force flow path. This effectively transfers the overall load of the main roof structure 1 to the side walls and end walls of the vehicle body, avoiding stress concentration, enhancing the load-bearing capacity of the roof, and ensuring the stability of the connection between the roof and the vehicle body, thereby improving the overall performance of the roof assembly.

[0031] Reference Figure 2 and Figure 3The side beam 21 is Z-shaped, and a support plate 211 is fixedly installed at the bottom of the side beam 21. The support plate 211 can be an integrally formed structure with the side beam 21, which ensures the connection strength between the support plate 211 and the side beam 21; or it can be a steel plate welded to the bottom of the side beam 21. The edge of the lower plate 12 overlaps with the support plate 211, and the edge of the upper plate 11 overlaps with the side beam 21. This Z-shaped side beam 21 design can better adapt to the connection between the roof and the vehicle body and increases the stability of the structure. It optimizes the structure of the load-bearing frame 2, can more efficiently transfer the overall load of the roof to the side walls and end walls of the vehicle body, and provides stable support for the main roof structure 1, which helps to improve the overall strength and reliability of the roof assembly.

[0032] Reference Figure 3 The lower panel 12 has first grooves 212 on both sides of its edges. These grooves 212 are adapted to the receiving plate 211, and the lower panel 12 overlaps the receiving plate 211 via the first grooves 212. The top of the side beam 21 has a second groove 213, which is adapted to the upper panel 11, and the edge of the upper panel 11 is located within the second groove 213. The design of the first grooves 212 and the second grooves 213 allows the upper panel 11 and the lower panel 12 to be accurately installed on the side beam 21, making the connection between the various parts of the roof main structure 1 tighter and enhancing the stability of the roof main structure 1. Furthermore, this groove-type connection method facilitates installation and improves assembly efficiency. Sealing gaskets, which can be made of rubber, are provided in both the first grooves 212 and the second grooves 213. These gaskets serve a sealing function, effectively preventing moisture or dust from entering the internal interlayer of the roof main structure 1, thereby avoiding accelerated aging of the intermediate core layer 13.

[0033] Reference Figure 3 Specifically, the cable tray 4 and the upper panel 11 are integrally formed by concave molding. This integral molding design makes the cable tray 4 more stable and facilitates wiring operations. A top cover 6 is also provided on the upper panel 11. The top cover 6 is adapted to the cable tray 4 and is fixed to the upper panel 11 by bolts to enclose the cable tray 4. The top cover 6 can be made of plastic or metal, and has a cable passage opening 61. The size, position, and number of the cable passage openings 61 can be designed according to actual wiring needs to facilitate the entry, exit, and organization of electrical wires.

[0034] Reference Figure 3 and Figure 4Specifically, the air duct 3 is arranged along the length of the main roof structure 1 and is located between the upper panel 11 and the lower panel 12. The air duct 3 can be formed by reserving a channel in the intermediate core layer 13, thus making full use of the space of the main roof structure 1; alternatively, it can be implemented using prefabricated ventilation ducts. The upper panel 11 is provided with a first ventilation opening 111 communicating with the air duct 3, and the lower panel 12 is provided with a second ventilation opening 121 communicating with the air duct 3. The first ventilation opening 111 and the second ventilation opening 121 can be different shapes such as circular or square. The arrangement of the air duct 3 meets the ventilation needs of the vehicle without the need for additional ventilation ducts, reduces independent metal components, helps to reduce the weight of the roof assembly, lowers the center of gravity of the vehicle, improves the handling stability and safety of the vehicle, and also improves production efficiency and reduces manufacturing costs.

[0035] Reference Figure 1 and Figure 5 The top of the upper panel 11 is also equipped with a heat dissipation plate 7, which is used to abut the power battery module. An airflow channel 71 is provided inside the heat dissipation plate 7. The heat dissipation plate 7 can be made of a metal with good thermal conductivity, such as copper or aluminum alloy, which can quickly conduct heat. The internal airflow channel 71 can be precision machined. The first vent 111 is connected to an air supply duct 112, which is connected to the airflow channel 71 via a quick connector. The airflow channel 71 is also connected to an exhaust duct 72 via a quick connector. The exhaust duct 72 passes through the air duct 3 and is used to connect to the vehicle's exhaust system. The airflow channel 71 inside the heat dissipation plate 7 is connected to the air supply duct 112 and the exhaust duct 72 via quick connectors, facilitating the installation and removal of the heat dissipation plate 7. Furthermore, the heat dissipation plate 7 can also be connected to a water cooling system to achieve rapid cooling of the power battery module.

[0036] Reference Figure 4 and Figure 5 The first ventilation opening 111 is also equipped with a draft air supply device 113, which can be a fan and is connected to the air supply duct 112. It can guide the cold air in the air duct 3 into the air supply duct 112. By setting a heat dissipation plate 7 at the top of the upper plate 11, which is in contact with the power battery module, and by delivering the cold air to the airflow channel 71 in the heat dissipation plate 7 through the draft air supply device 113 and the air supply duct 112, the heat dissipation plate 7 can exchange heat with the power battery module, effectively dissipating heat from the power battery module, improving the safety of the power battery module, and further improving the ventilation and thermal management functions of the roof assembly.

[0037] The implementation principle of a highly integrated roof assembly for rail transit vehicles according to this application embodiment is as follows: This embodiment integrates functional structures such as the load-bearing frame 2, air duct 3, and cable tray 4 with the main roof structure 1, reducing the use of independent parts and additional components. For example, by using specific materials and connection methods for the main roof structure 1, the roof itself possesses sound insulation and heat insulation properties, eliminating the need for additional materials; the reasonable arrangement of the air duct 3 avoids the installation of additional ventilation pipes; and the integrated molding of the cable tray 4 simplifies the wiring process. These designs not only reduce the weight of the roof and lower the center of gravity of the vehicle, improving the vehicle's handling stability and safety, but also increase production efficiency and reduce manufacturing costs. Simultaneously, the installation of the heat dissipation plate 7 improves the roof's thermal management function, ensuring the safe use of the power battery module, representing a significant improvement and enhancement compared to traditional roof designs.

[0038] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A highly integrated roof assembly for rail transit vehicles, characterized in that, include: Main structure of the roof (1); The load-bearing frame (2) is integrated with the main roof structure (1) and is used to install and fix the main roof structure (1) on the vehicle body. The load-bearing frame (2) is used to directly bear the overall load of the main roof structure (1) and transfer the load to the side walls and end walls of the vehicle body. The air duct (3) is located inside the main roof structure (1) and is used for ventilation; Cable channel (4) is provided inside the main structure of the roof (1) for arranging electrical wiring harnesses; The mounting frame (5) is set on the top of the main structure (1) of the vehicle roof. The mounting frame (5) is provided with several mounting interfaces for installing the air conditioning unit and the power battery module. The main structure (1) of the roof includes an upper panel (11), a lower panel (12), and an intermediate core layer (13) disposed between the upper panel (11) and the lower panel (12). The intermediate core layer (13) is bonded and fixed to the upper panel (11) and the lower panel (12) respectively. The load-bearing frame (2) includes side beams (21) set on both sides of the main structure (1) of the roof, and several cross beams (22) fixedly set between the side beams (21) on both sides. Each cross beam (22) passes through the top panel (11) and the bottom panel (12) and is fixedly connected to the top panel (11) and the bottom panel (12) respectively. The side beams (21) are used to be installed and fixed on the vehicle body. The side beam (21) is in the shape of a "Z", and a support plate (211) is fixedly provided at the bottom of the side beam (21). The edge of the lower panel (12) overlaps on the support plate (211), and the edge of the upper panel (11) overlaps on the side beam (21). The lower panel (12) has a first groove (212) on each side edge. The first groove (212) is adapted to the support plate (211), and the lower panel (12) overlaps the support plate (211) through the first groove (212). The top of the side beam (21) has a second groove (213), which is adapted to the upper panel (11), and the edge of the upper panel (11) is located in the second groove (213).

2. The highly integrated roof assembly of a rail transit vehicle according to claim 1, characterized in that, Both the first groove (212) and the second groove (213) are provided with sealing gaskets.

3. The highly integrated roof assembly of a rail transit vehicle according to claim 1, characterized in that, The air duct (3) is arranged along the length of the main structure (1) of the roof and is located between the upper panel (11) and the lower panel (12). The upper panel (11) is provided with a first ventilation opening (111) that communicates with the air duct (3), and the lower panel (12) is provided with a second ventilation opening (121) that communicates with the air duct (3).

4. The highly integrated roof assembly of a rail transit vehicle according to claim 3, characterized in that, The top of the upper panel (11) is also provided with a heat dissipation plate (7), which is used to abut against the power battery module. An airflow channel (71) is provided inside the heat dissipation plate (7). The first vent (111) is also connected to an air supply duct (112). The air supply duct (112) is connected to the airflow channel (71). The airflow channel (71) is also connected to an exhaust duct (72), which is used to connect to the exhaust system inside the vehicle.

5. The highly integrated roof assembly of a rail transit vehicle according to claim 4, characterized in that, The first vent (111) is also equipped with a flow-guiding and air-supplying device (113) to guide airflow into the air supply duct (112).

6. The highly integrated roof assembly of a rail transit vehicle according to claim 1, characterized in that, The cable channel (4) is integrally formed with the upper panel (11) by concave pressing. The upper panel (11) is also provided with a top cover plate (6). The top cover plate (6) is adapted to the cable channel (4) and is fixed to the upper panel (11) by bolts to seal the cable channel (4). The top cover plate (6) is provided with a cable passage (61).

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