Rail vehicle bolster structure and processing method

Abstract

The present invention discloses a rail vehicle bolster structure and processing method, providing a bolster structure with simple structure, high strength, simple assembly welding and machining processes. By optimizing the profile structure, welding process and procedure, lightweight is achieved, the workload of assembly and welding is reduced, welding deformation is reduced, and the connection interface between the bolster and the surrounding structure is improved. The bolster structure includes a left profile, a right profile, a cover plate, an air spring seat, an empty spring tube and a bushing. The left profile and the right profile integrate multiple installation interfaces and welding structures, and the installation interface includes a floor interface, a traction beam interface and a cover plate interface. The left and right profiles on the lower surface are directly connected by a double-sided V-shaped weld, without an intermediate cover plate, and no reinforcing beam is set between the left and right profiles to reduce the welding amount and welding deformation; the upper part is connected by a cover plate to realize the assembly of the air spring seat and the empty spring tube; the air spring seat and the empty spring connection surface are installed by a stainless steel sleeve cold pressing process to ensure the reliability of the sealing structure.

Description

Technical Field

[0001] The invention relates to a rail vehicle bolster structure and a processing method thereof, and belongs to the field of mechanical manufacturing. Background Art

[0002] In the field of rail vehicles, the bolster is one of the most critical components, connecting the car body and the bogie, and its strength directly affects the quality and safety of driving. In the rail vehicles currently designed and used in China, the bolster structure is mostly made of plate welding or square profile structure. This type of structure has problems such as complex process, large welding and adjustment workload, high cost and heavy weight.

[0003] With the continuous improvement of the running speed and quality of rail vehicles, higher requirements are placed on the design and manufacture of sleepers. In view of this, this patent application is hereby filed. Summary of the invention

[0004] The rail vehicle bolster structure and processing method described in the present invention are designed to solve the above problems existing in the existing bolsters, and provide a bolster structure with simple structure, high strength, simple assembly welding and machining processes. By optimizing the profile structure, welding process and procedures, lightweighting is achieved, the workload of assembly and welding is reduced, welding deformation is reduced, and the connection interface between the bolster and the surrounding structure is improved.

[0005] The invention also aims to reduce the weight of the vehicle body effectively, thereby facilitating the lightweighting of rail vehicles and increasing the running speed.

[0006] In order to achieve the above-mentioned invention object, the present invention adopts the following technical scheme:

[0007] A rail vehicle bolster structure comprises a bolster main structure, wherein the bolster main structure is formed by butting a left profile, a cover plate and a right profile, an air spring seat and an empty spring tube are preset in the bolster main structure, the lower parts of the left profile and the right profile are butt-welded, the upper parts of the left profile and the right profile are connected by a cover plate, one end of the empty spring tube is connected to the air spring seat, and the other end is fixed to the bolster through a bracket, a shaft sleeve is embedded on the inner surface of the air spring seat, the shaft sleeve is pressed into the shaft sleeve bottom hole of the bolster main structure, and the shaft sleeve is interference fit with the shaft sleeve bottom hole.

[0008] The lower parts of the left and right profiles are butted together to form a double-sided V-shaped groove, and the lower parts of the left and right profiles are welded at the double-sided V-shaped groove; the upper parts of the left and right profiles are connected to the cover plate through a single-sided V-shaped weld.

[0009] The air spring seat and the empty spring tube are connected by a circumferential fillet welding, and the circumferential fillet welding is achieved by rotating the air spring seat and the empty spring tube.

[0010] An elliptical hollow reed tube mounting hole is arranged on the right profile corresponding to the hollow reed tube.

[0011] The air spring seat and the main structure of the bolster are connected by a Y-shaped circumferential weld.

[0012] After the main structure of the bolster is assembled, the lower plane of the main structure of the bolster is machined as a whole.

[0013] The left profile is provided with an overlap interface, and the left profile is plugged into the floor through the overlap interface, and the overlap interface is designed with a gradual thickness change.

[0014] The main structure of the bolster is transitionally connected to the traction beam through plates of unequal thickness, and the lower part of the left profile provides a connection port for the traction beam.

[0015] The air spring seat and the shaft sleeve are interference connected through a cold pressing process.

[0016] A method for processing a rail vehicle bolster structure, used for processing the rail vehicle bolster structure as claimed in any one of claims 1 to 9, comprising the following process steps:

[0017] S1: Place the left profile and the right profile on the working platform, connect the double-sided groove ends to form a double-sided V-shaped groove, adjust the horizontal gap between the left profile and the right profile, press them with the tooling, perform positioning welding, and preheat them in the heating equipment. After preheating, perform the first group welding to form the bolster beam;

[0018] S2: Fix the bolster assembly welded in step S1 on a processing platform, and machine the air spring seat hole according to the designed size;

[0019] S3: Place the air spring seat to the position of the air spring seat hole completed in S2, insert the empty spring tube into the bolster through the elliptical empty spring tube installation hole of the right profile, assemble and fix it with the air spring seat, and then use the space of the elliptical empty spring tube installation hole to realize the rotation of the air spring seat and the empty spring tube inside the cavity with the empty spring tube as the axis. The welding gun welds from the upper space of the left and right profiles, and welds the circumferential fillet weld while rotating to complete the assembly of the empty spring seat;

[0020] S4: Install the air spring seat assembly completed in S3 into the air spring seat hole completed in step S2, and fix it on the bolster assembly by spot welding after adjusting the size and position to form a Y-shaped groove, flip the bolster assembly so that its lower surface faces upward, and perform Y-shaped weld circumference welding;

[0021] S5: Place the bolster assembly on the IGM automatic robot tooling platform, place the cover plate, make the groove ends face each other to form a V-shaped groove, press it with the tooling, and perform automatic welding to form the main structure of the bolster;

[0022] S6: Place the main structure of the bolster on the machining platform and fix it with tooling; machine the lower plane of the bolster as a whole to ensure that the flatness and size meet the design requirements and provide an interface for installation;

[0023] S7: Place the lower surface of the main structure of the bolster completed in S6 on the press-fitting platform upwards, take out the sleeve placed in liquid nitrogen in advance, install it on the sleeve bottom hole processed in step S6, and use the pressing equipment to press the sleeve into the sleeve bottom hole within the specified time to achieve the required size.

[0024] The difference from the prior art lies in that the left profile and the right profile are multi-cavity profiles, which improves the connection between the main structure of the bolster and the surrounding structure; a cover plate is used on one side of the bolster, and the air spring seat and the bolster are welded together.

[0025] In order to improve the strength of the bolster and reduce welding deformation, the main structure is an aluminum alloy profile cavity structure.

[0026] In order to reduce the amount of welding and welding deformation, the lower surface of the main structure of the pillow beam is designed as a thickened profile, the reinforcement plate is eliminated, and the left and right profiles are directly butt-welded without a cover plate.

[0027] In order to realize the assembly of the air spring seat and the bolster, and the welding of the air spring seat and the air spring tube, a cover plate is used to connect the upper surface of the bolster main structure.

[0028] In order to realize the assembly of the air spring seat and the air spring tube, an in-cavity rotation welding method was developed, that is, an elliptical hole was processed in the right profile so that the two can achieve relative rotation when welding.

[0029] In order to absorb the tolerance in the length direction of the vehicle body, an overlap connection interface is provided between the right profile and the floor.

[0030] In order to achieve strength requirements and processability, a gradient thickness overlap interface is set between the left profile and the outer floor of the sleeper to achieve a flat butt weld between the sleeper beam and the outer floor of the sleeper.

[0031] In order to optimize the connection structure between the traction beam and the pillow block, the two are connected by a transition connection through plates of unequal thickness, and the lower part of the left profile provides a connection port for the traction beam.

[0032] In order to improve welding quality and reduce welding deformation, double-sided V-shaped welding is adopted on the lower part of the left and right profiles.

[0033] In order to achieve flat butt welding between the air spring seat and the bolster assembly and solve the problem that the back weld cannot be repaired after welding, a Y-type circumferential weld is used.

[0034] The difference from the prior art is that the profile is integrated with the connection structure with the floor.

[0035] The air spring seat and the stainless steel sleeve are interference fit. The stainless steel sleeve is cooled by liquid nitrogen and then pressed into the bottom hole of the air spring seat in a short time to achieve interference fit at room temperature.

[0036] A through pipe is arranged in the main structure of the bolster to provide passages for various water and gas pipelines.

[0037] The through-tube is made of stainless steel, fixed to the main structure of the bolster by bolts and sealed by a sealing plate, and coated with sealant to solve the problem that welding sealing cannot be implemented at this position due to strength problems.

[0038] A self-tapping threaded bushing is embedded in the installation hole of the sealing plate to achieve reliable connection between the bolt and the aluminum structure.

[0039] An elliptical hole is opened to realize the in-cavity welding of the empty spring seat and the empty spring tube, and a fixing bracket is added at one end of the empty spring tube to ensure the strength.

[0040] In summary, the rail vehicle bolster structure and processing method have the following advantages and beneficial effects:

[0041] 1. The multi-cavity profile with integrated multiple installation interfaces and welding structure is adopted. Compared with the existing structure, it has simple structure, high integration, high strength, and is easy to assemble and weld.

[0042] 2. Reasonable structure and process design reduce welding workload and reduce welding deformation; the bolster is machined as a whole after welding, and the flatness is easy to ensure.

[0043] 3. Improve the connection performance and reliability by improving the connection method between the bolster and the bogie mounting parts.

[0044] 4. Reduce production costs or achieve manufacturing feasibility by developing new welding processes and reasonable connection methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 is a schematic diagram of the overall structure of the bolster;

[0046] Figure 2 is a schematic diagram of the lower surface of the bolster;

[0047] Figure 3 yes Figure 2 Schematic diagram of the AA section;

[0048] Figure 4 yes Figure 2 Schematic diagram of the cross section along the BB direction;

[0049] Figure 5 yes Figure 2 Schematic diagram of the CC section;

[0050] Figure 6 It is a schematic diagram of the connection between the left profile and the right profile;

[0051] Figure 7It is a schematic diagram of the connection between the air spring tube, air spring seat and the left and right profiles;

[0052] Figure 8 It is a schematic diagram of the connection between the through-tube and the left and right profiles;

[0053] Fig. 9 yes Figure 8 Schematic diagram of the enlarged structure of E.

[0054] In the figure: 1. Left profile; 101. Overlapping interface; 102. Connecting interface; 2. Right profile; 201. Air spring tube mounting hole; 3. Cover plate; 4. Air spring seat; 5. Air spring tube; 6. Self-tapping threaded bushing; 7. Bracket; 8. Bushing; 9. Bushing bottom hole; 10. Floor; 11. Traction beam; 12. Plates of unequal thickness; 13. Side hole; 14. Double-sided V-shaped groove; 15. Y-shaped groove; 16. Through pipe; 17. Sealing plate. DETAILED DESCRIPTION

[0055] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0056] like Figure 1-9 As shown, a rail vehicle bolster structure includes a bolster main structure, wherein the bolster main structure is composed of a left profile 1, a cover plate 3 and a right profile 2 connected together, an air spring seat 4 and an empty spring tube 5 are preset in the bolster main structure, the lower parts of the left profile 1 and the right profile 2 are butt-welded, the upper parts of the left profile 1 and the right profile 2 are connected by a cover plate 3, one end of the empty spring tube 5 is connected to the air spring seat 4, and the other end is fixed to the bolster through a bracket 7, a sleeve 8 is embedded on the inner surface of the air spring seat 4, the sleeve 8 is pressed into the sleeve bottom hole 9 of the bolster main structure, and the sleeve 8 is interference fit with the sleeve bottom hole 9.

[0057] The lower parts of the left profile 1 and the right profile 2 are butted together to form a double-sided V-shaped groove 14, and the lower parts of the left profile 1 and the right profile 2 are welded at the double-sided V-shaped groove 14; the upper parts of the left profile 1 and the right profile 2 are connected to the cover plate 3 through a single-sided V-shaped weld.

[0058] The air spring seat 4 and the empty spring tube 5 are connected by a circumferential fillet welding, and the circumferential fillet welding is achieved by rotating the air spring seat 4 and the empty spring tube 5 .

[0059] An elliptical hollow reed tube mounting hole 201 is provided on the right profile 2 corresponding to the hollow reed tube 5 .

[0060] The air spring seat 4 is connected to the main structure of the bolster by a Y-shaped circumferential weld.

[0061] After the main structure of the bolster is assembled, the lower plane of the main structure of the bolster is machined as a whole.

[0062] The left profile 1 is provided with an overlap joint 101 , through which the left profile 1 is plugged into the floor 10 , and the overlap joint is designed with a gradual thickness change.

[0063] The main structure of the bolster is transitionally connected to the traction beam 11 through a plate 12 of unequal thickness, and the lower part of the left profile 1 provides a connection port 102 for the traction beam 12 .

[0064] The air spring seat 4 and the shaft sleeve 8 are interference-connected by a cold pressing process.

[0065] A through pipe 16 is arranged in the main structure of the bolster to provide a passage for various water and gas pipelines.

[0066] The through-tube 16 is made of stainless steel, fixed to the main structure of the bolster by bolts and sealed by a sealing plate 17, and coated with sealant to solve the problem that welding sealing cannot be implemented at this position due to strength reasons.

[0067] A self-tapping threaded bushing 6 is embedded in the mounting hole of the sealing plate to achieve a reliable connection between the bolt and the aluminum structure.

[0068] A method for processing a rail vehicle bolster structure, comprising the following process steps:

[0069] S1: Place the left profile 1 and the right profile 2 on the working platform, connect the double-sided groove ends to form a double-sided V-shaped groove 14, adjust the horizontal gap between the left profile 1 and the right profile 2, press them with a tooling, perform positioning welding, and preheat them in a heating device. After preheating, perform the first assembly welding to form a bolster beam;

[0070] S2: Fix the bolster assembly welded in step S1 on a processing platform, and machine the air spring seat hole according to the designed size;

[0071] S3: Place the air spring seat 4 to the position of the air spring seat hole completed in S2, insert the empty spring tube 5 into the bolster through the elliptical empty spring tube installation hole 201 of the right profile 2, and assemble and fix it with the air spring seat 4, and then use the space of the elliptical empty spring tube installation hole 201 to realize the rotation of the air spring seat 4 and the empty spring tube 5 inside the cavity with the empty spring tube as the axis, and weld the welding gun from the upper space of the left and right profiles, and weld the circumferential fillet weld while rotating to complete the assembly of the empty spring seat;

[0072] S4: Install the air spring seat assembly completed in step S3 into the air spring seat hole completed in step S2, and fix it on the bolster assembly by spot welding after adjusting the size and position to form a Y-shaped groove 15, turn the bolster assembly over so that its lower surface faces upward, and perform Y-shaped weld circumference welding;

[0073] S5: Place the bolster assembly on the IGM automatic robot tooling platform, place the cover plate 3, make the groove ends face each other to form a V-shaped groove, press it by the tooling, and perform automatic welding to form the main structure of the bolster;

[0074] S6: Place the main structure of the bolster on the machining platform and fix it with tooling; machine the lower plane of the bolster as a whole to ensure that the flatness and size meet the design requirements and provide an interface for installation;

[0075] S7: Place the lower surface of the main structure of the pillow block completed in S6 on the pressing platform upwards, take out the shaft sleeve 8 placed in liquid nitrogen in advance, install it on the shaft sleeve bottom hole 9 processed in step S6, and use the pressing equipment to press the shaft sleeve 8 into the shaft sleeve bottom hole 9 within the specified time to achieve the required size.

[0076] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for processing a rail vehicle bolster structure, characterized in that: Used to process rail vehicle bolster structures, including the following process steps: S1: placing the left profile (1) and the right profile (2) on a working platform, connecting the double-sided groove ends to form a double-sided V-shaped groove (14), adjusting the lateral gap between the left profile (1) and the right profile (2), performing positioning welding after pressing with a tooling, and preheating in a heating device; after preheating, performing the first assembly welding to form a bolster beam assembly; S2: Fix the bolster assembly welded in step S1 on a processing platform, and machine the air spring seat hole according to the designed size; S3: Place the air spring seat (4) at the position of the air spring seat hole completed in S2, insert the empty spring tube (5) into the bolster through the elliptical empty spring tube installation hole (201) of the right profile (2), assemble and fix it with the air spring seat (4), and then use the space of the elliptical empty spring tube installation hole (201) to realize the rotation of the air spring seat (4) and the empty spring tube (5) inside the cavity with the empty spring tube as the axis. Use the welding gun to weld from the upper space of the left profile and the right profile, and weld the circumferential fillet weld while rotating to complete the assembly of the empty spring seat; S4: Install the air spring seat assembly completed in step S3 into the air spring seat hole completed in step S2, and fix it on the bolster assembly by spot welding after adjusting the size and position to form a Y-shaped groove (15), turn the bolster assembly over so that its lower surface faces upward, and perform Y-shaped weld circumference welding; S5: placing the bolster assembly onto the IGM automatic robot tooling platform, placing the cover plate (3), making the groove ends face each other to form a V-shaped groove, pressing it with the tooling, and automatically welding it to form the main structure of the bolster; S6: Place the main structure of the bolster on the machining platform and fix it with tooling; machine the lower plane of the bolster as a whole to ensure that the flatness and size meet the design requirements and provide an interface for installation; S7: Place the lower surface of the main structure of the bolster completed in S6 on the press-fitting platform upward, take out the shaft sleeve (8) placed in liquid nitrogen in advance, install it into the shaft sleeve bottom hole (9) processed in step S6, and use a press-fitting device to press the shaft sleeve (8) into the shaft sleeve bottom hole (9) within a specified time to achieve the required size; The rail vehicle bolster structure comprises a bolster main structure, the bolster main structure is formed by butting a left profile (1), a cover plate (3) and a right profile (2), an air spring seat (4) and an empty spring tube (5) are preset in the bolster main structure, the lower parts of the left profile (1) and the right profile (2) are butt-welded, the upper parts of the left profile (1) and the right profile (2) are connected by a cover plate (3), one end of the empty spring tube (5) is connected to the air spring seat (4), and the other end is fixed to the bolster through a bracket (7), a shaft sleeve (8) is embedded in the inner surface of the air spring seat (4), the shaft sleeve (8) is pressed into the shaft sleeve bottom hole (9) of the bolster main structure, and the shaft sleeve (8) and the shaft sleeve bottom hole (9) are interference fit; The lower parts of the left profile (1) and the right profile (2) are butted together to form a double-sided V-shaped groove (14); the lower parts of the left profile (1) and the right profile (2) are welded at the double-sided V-shaped groove (14); the upper parts of the left profile (1) and the right profile (2) are connected to the cover plate (3) via a single-sided V-shaped weld; The air spring seat (4) and the empty spring tube (5) are connected by a circumferential fillet welding, and the circumferential fillet welding is achieved by rotating the air spring seat (4) and the empty spring tube (5); An elliptical hollow reed tube mounting hole (201) is provided on the right profile (2) corresponding to the hollow reed tube (5); The air spring seat (4) is connected to the main structure of the bolster by a Y-shaped circumferential weld; The left profile (1) is provided with a lap joint (101), and the left profile (1) is plugged into the floor (10) via the lap joint, and the lap joint is designed with a gradually changing thickness; The main structure of the bolster is transitionally connected to the traction beam (11) via a plate of unequal thickness (12), and the lower part of the left profile (1) provides a connection opening (102) for the traction beam (11); The air spring seat (4) and the shaft sleeve (8) are interference-connected by a cold pressing process, and a through-tube (16) is arranged in the main structure of the bolster to provide a passage for water and air pipelines.

2. A method for processing a rail vehicle bolster structure according to claim 1, characterized in that: After the main structure of the bolster is assembled, the lower plane of the main structure of the bolster is machined as a whole.

Images