A roof mounting process and a joggle device for a rail vehicle body

Abstract

The present application relates to a kind of roof mounting process and joggle device of rail vehicle body, comprising the following steps: S1, four roof joists are fixedly connected on the installation reference surface of joggle device by bolt, form quadrilateral overall frame;S2, after pre-grouping, roof joist is together with joggle and falls into the main structure of car body;S3, roof joist is fixed with the main structure of car body by welding;S4, after welding, joggle is removed from roof joist;S5, roof is fallen into the roof joist of installation completion, and roof is fixedly connected with roof joist by bolt.The present application can realize quick, accurate installation roof, and it is favorable to promote operation efficiency, reduce operation cost.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of rail vehicle manufacturing, and particularly relates to a roof mounting process and a joggle device for a rail vehicle body. BACKGROUND

[0002] The steel structure of the rail vehicle body includes a chassis, side walls, end walls and a roof. The roof is generally an overall structure of aluminum profiles. When the body is assembled, the side walls and the end walls are first fixedly connected to the chassis to form a main structure of the body, and then the roof is mounted on the top of the main structure of the body.

[0003] In order to fix the roof, a roof support beam in the shape of a square frame is mounted on the top of the main structure of the body. The roof support beam is fixedly connected to the main structure of the body by welding. The roof of the rail vehicle body is fixedly mounted on the roof support beam by bolt fastening, and the mounting of the roof and the main structure of the body is completed.

[0004] In order to realize bolt fastening, a mounting circular hole is formed on the roof and the roof support beam, respectively. There are a total of 36 groups of mounting circular holes. The corresponding mounting circular holes are fastened and connected by 36 groups of bolts, so as to fix and connect the roof and the roof support beam together to form a complete steel structure of the body.

[0005] In the mounting process of the roof, it is necessary to ensure that the 36 groups of mounting circular holes are completely coincident. Otherwise, the bolts cannot pass through the corresponding mounting holes to be connected.

[0006] The roof support beam is generally a square frame structure formed by two groups of 8200mm long strip structures and two groups of 1800mm long strip structures. The overall size of the roof support beam is large, and the installation precision requirement is also high. If manual positioning is used during installation, the installation precision cannot be guaranteed. Moreover, the roof support beam is connected to the main structure of the body by welding. The overall flatness, diagonal line and mounting hole of the roof support beam after welding are deviated due to welding deformation, which further causes the mounting holes on the roof side beam and the mounting holes on the roof to be unable to correspond, so that the roof cannot be mounted on the roof side beam. This greatly increases the operation difficulty and operation time, increases the operation cost, and also reduces the operation efficiency. SUMMARY

[0007] The technical problem solved by the present application is to provide a roof mounting process for a rail vehicle body, which can realize fast and accurate installation of the roof, is beneficial to improving the operation efficiency and reducing the operation cost.

[0008] The present application also provides a joggle device which has a simple overall structure and can ensure the installation precision of the roof.

[0009] To achieve the above-mentioned purpose, the technical solution of the present application is as follows:

[0010] A roof mounting process of a rail vehicle body, comprising the following steps:

[0011] S1, four roof support beams are fixedly connected on the mounting reference surface of the template device by bolts to form a quadrilateral overall frame;

[0012] S2, the pre-assembled roof support beams are lowered into the main structure of the vehicle body together with the template;

[0013] S3, the roof support beams are welded and fixedly connected with the main structure of the vehicle body;

[0014] S4, after welding, the template is removed from the roof support beams;

[0015] S5, the roof is lowered into the installed roof support beams, and the roof is fixedly connected with the roof support beams by bolts.

[0016] Further, the mounting reference surface of the template has the same number of mounting holes as the roof support beams.

[0017] Further, the overall flatness of the mounting reference surface is less than 2mm.

[0018] Another technical solution of the present application is:

[0019] A template device for implementing the roof mounting process of the rail vehicle body as described above, comprising a template main body and a plurality of template supports, the template main body is supported on the template supports, the template main body is a frame structure, a lifting lug for connecting with a lifting device is installed on the template main body, and the template main body has a mounting reference surface obtained by machining.

[0020] Further, the template main body is made of aluminum alloy profiles.

[0021] Further, the template main body is composed of two layers of frames, the bottom surface of the lower layer of frames is the mounting reference surface, and the upper layer of frames is fixedly connected with the lower layer of frames through a plurality of connecting beams.

[0022] Further, the width and length of the upper layer of frames are smaller than the width and length of the lower layer of frames, and the overall template main body is tapered with the width increasing from top to bottom.

[0023] Further, the upper layer of frames and the lower layer of frames are both spliced and welded by four edge beams and a plurality of intermediate beams.

[0024] Further, the template support is composed of a bottom plate, a support column, a support cross beam and a V-shaped support seat, the bottom of the support column is fixed on the bottom plate, the support cross beam is installed on the top of the support column, a plurality of V-shaped support seats are installed on the support cross beam, and the intermediate beams of the template main body are supported in the V-shaped support seats.

[0025] Further, the V-shaped support seat is formed by two metal plates being obliquely welded upward on the support beam.

[0026] In summary, the roof mounting process and joggle device of the rail vehicle body have the following advantages compared with the prior art:

[0027] (1) The joggle device is used to pre-assemble four groups of roof support beams into a four-square frame shape, and during the welding process of the roof support beam and the main structure of the vehicle body, the rigid constraint provided by the joggle device effectively prevents the size change caused by the welding deformation of the roof support beam, reduces the influence of welding deformation, and ensures the positioning size of the overall flatness, diagonal line and mounting hole position of the welded roof support beam, realizes the accurate matching of the roof and the roof support beam, ensures that the 36 groups of bolt mounting holes of the roof and the roof support beam are not deviated, and can be smoothly connected, realizes the overall rapid and accurate installation of the roof, and is beneficial to improve the operation efficiency and reduce the operation cost.

[0028] (2) The joggle device provided by the present application has a frame structure, and the mounting reference surface is machined on the frame by machining, which not only has a simple overall structure and is easy to operate, but also can be fixedly connected with the roof support beam by using the mounting reference surface, thereby providing effective rigid constraint for the roof side beam during the welding process, and further ensuring the roof mounting precision. BRIEF DESCRIPTION OF DRAWINGS

[0029] The accompanying drawings, which are part of the present application, serve to further understand the present application, and the illustrative embodiments of the present application and their descriptions serve to explain the present application, but do not constitute an improper limitation on the present application. Obviously, the drawings in the following description are only some embodiments, and other drawings can be obtained by those skilled in the art without creative labor.

[0030] Figure 1 is a structural schematic view of the joggle device of the present application;

[0031] Figure 2 is a side view of Figure 1 ;

[0032] Figure 3 is a side view of Figure 2 ;

[0033] Figure 4 is a downward view of Figure 1 ;

[0034] Figure 5 is a schematic view of the pre-assembly and mounting steps of the roof support beam of the present application;

[0035] Figure 6A schematic diagram illustrating the installation steps for fixing the roof support beam to the main structure of the vehicle body according to the present invention;

[0036] Figure 7 A schematic diagram of the installation steps after the roof support beam of the present invention is fixed to the main structure of the vehicle body;

[0037] Figure 8 A schematic diagram illustrating the installation steps for removing the template body according to the present invention;

[0038] Figure 9 A schematic diagram of the roof installation steps of this invention.

[0039] like Figures 1 to 9 As shown, the components are: 1. Roof support beam; 2. Main body structure; 3. Template body; 4. Template bracket; 5. Lifting lug; 6. Mounting hole; 7. Roof; 8. Bolt; 9. Positioning seat.

[0040] Upper frame 31, lower frame 32, mounting reference surface 33, connecting beam 34, long side beam 35, short side beam 36, middle beam 37;

[0041] Base plate 41, support column 42, support beam 43, V-shaped support seat 44, beam 45, reinforcing beam 46, metal plate 47.

[0042] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0044] like Figures 1 to 4 As shown, the present invention provides a template device for fixing and constraining the roof support beam 1, and installing the roof support beam 1 onto the main structure 2 of the vehicle body.

[0045] The template device includes a template body 3 and multiple template supports 4. The template body 3 is matched with the structural dimensions of the roof support beam 2. According to the dimensions of the template body 3, in this embodiment, two template supports 4 are provided, and the template body 3 is supported on the two template supports 4.

[0046] A plurality of lifting lugs 5 for connecting with hoisting equipment are installed on the body 3, and the body 3 assembled with the roof support beam 1 is lifted off from the body support 4 by a hoisting equipment (not shown in the figure) such as a crane, and is transported to the main structure 2 of the vehicle body where the roof 7 is to be installed, and meanwhile, the body 3 is transported away from the main structure 2 of the vehicle body by the hoisting equipment and is placed on the body support 4 again. In this embodiment, four lifting lugs 5 are installed on the body 3, and are connected with four lifting belts of the hoisting equipment such as a crane, so as to ensure that the body 3 is lifted stably.

[0047] In this embodiment, the body 3 is of a frame structure, and is preferably made of aluminum alloy profiles, so as to reduce the weight of the body 3 and ensure the rigidity of the body 3.

[0048] In this embodiment, in order to further improve the rigidity of the body 3, the body 3 is preferably composed of two layers of frames, i.e., an upper frame 31 and a lower frame 32, and the upper frame 31 and the lower frame 32 are fixedly connected by a plurality of connecting beams 34, which are also made of aluminum alloy profiles, and the two ends of the connecting beams 34 are respectively welded and fixed on the side beams 35 of the upper frame 31 and the lower frame 32.

[0049] The width and length of the upper frame 31 are smaller than those of the lower frame 32, and the body 3 is conical in shape with the width increasing downward. The upper frame 31 and the lower frame 32 are both composed of two long side beams 35, two short side beams 36 and a plurality of intermediate beams 37.

[0050] The intermediate beams 37 in the upper frame 31 include a plurality of transverse beams (extending in the width direction of the upper frame 31), and the two ends of the transverse beams are welded on the two long side beams 35 of the upper frame 31. The four lifting lugs 5 are welded at the connecting points of the two long side beams 35 and two transverse beams of the upper frame 31, so as to ensure the structural strength of the installation position of the lifting lugs 5.

[0051] The intermediate beams 37 in the lower frame 32 include a plurality of transverse beams and diagonal bracing beams, and the two ends of the transverse beams are also welded on the two long side beams 35 of the lower frame 32. Diagonal bracing beams are welded between the short side beams 35 and the transverse beams and between two adjacent transverse beams.

[0052] The bottom surface of the lower frame 32 is a mounting reference surface 33 for fixing the roof support beam 1, which is obtained by machining to ensure high accuracy of the mounting reference surface 33, so that the overall flatness of the mounting reference surface 33 is less than 2 mm, thereby ensuring the overall flatness of the roof support beam 1 before and after welding, and ensuring that the relative dimensional deviation of the mounting hole 6 of the bolt 8 of the roof support beam 1 after pre-assembly is less than 0.5 mm. Four sets of roof support beams 1 are fixed to the mounting reference surface 33 by the bolts 8 to form a four-side frame-shaped overall structure, and the relative positioning size of the roof support beam 1 is effectively ensured.

[0053] The size of the lower frame 32 is the same as that of the roof support beam 1, and a plurality of mounting holes 6 are arranged on the two long side beams 35 and the two short side beams 36, and the number of the mounting holes 6 is the same as that of the mounting holes arranged on the roof support beam 1 for fixed connection with the roof 7. When the backrest body 3 is fixedly connected with the roof support beam 1, the bolts 8 can be installed in all the mounting holes 6, or the bolts 8 can be installed in only part of the mounting holes 6.

[0054] In the embodiment, the backrest support 4 is used for supporting the backrest body 3 and is made of carbon steel, and the two backrest supports 4 are the same in structure. The backrest support 4 is composed of a bottom plate 41, support columns 42, a support cross beam 43 and V-shaped support seats 44. The bottom plate 41 is fixed on the ground of the workbench position by bolts, the support columns 42 are two and arranged in the short side direction, the bottoms of the two support columns 42 are fixed on the bottom plate 41, the support cross beam 43 is welded or fixed on the tops of the two support columns 42 by bolts and extends in the short side direction. In order to improve the support strength, a cross beam 45 is welded between the two support columns 42, and a plurality of reinforcing beams 46 are welded between the bottoms of the support columns 42 and the bottom plate 41.

[0055] A plurality of V-shaped support seats 44 are installed above the support cross beam 43, and in the embodiment, two V-shaped support seats 44 are installed on each support cross beam 43. The V-shaped support seats 44 are upwardly open, and one of the intermediate beams 37 in the lower frame 32 of the backrest body 3 is embedded and supported in the V-shaped support seat 44. The V-shaped structure facilitates taking and placing the corresponding intermediate beam 35 of the backrest body 3, and ensures that the backrest body 3 does not shake left and right after being placed on the backrest support 4. In the embodiment, the V-shaped support seat 44 is preferably formed by two metal plates 47 being obliquely welded on the support cross beam 43, which is easy to process and manufacture.

[0056] As shown in the drawings, Figures 5 to 9 The application also simultaneously provides a roof mounting process for a rail vehicle body, which specifically comprises the following steps:

[0057] S1, as shown in the drawings, Figure 5As shown, four roof support beams 1 are fixedly connected to the mounting reference surface 33 of the mockup body 3 by bolts 8 to form a quadrilateral overall frame.

[0058] S2, as shown, Figure 6 As shown, the pre-assembled roof support beams 1 and the mockup body 3 are placed into the main structure 2 of the vehicle body, and the positioning is completed. In order to facilitate positioning, a plurality of positioning seats 9 protruding in the central direction are provided on the main structure 2 of the vehicle body, and the upper surface of the positioning seat 9 is a positioning plane. When mounting, the lower surface of the roof support beam 1 is placed on the positioning plane of the plurality of positioning seats 9.

[0059] S3, as shown, Figure 7 As shown, the roof support beam 1 is fixedly connected to the main structure 2 of the vehicle body by welding. The roof support beam 1 is not removed during the welding process, and the roof support beam 1 is rigidly constrained by the mockup body 3 to prevent the positioning size of the roof support beam 1 from deviating due to welding deformation.

[0060] S4, as shown, Figure 8 As shown, after the welding is cooled, the bolts 8 between the mockup body 3 and the roof support beam 1 are removed, and the mockup body 3 is removed from the roof support beam 1.

[0061] S5, as shown, Figure 9 As shown, the roof 7 is placed into the installed roof support beam 1, and the roof 7 is fixedly connected to the roof support beam 1 by bolts.

[0062] The present application utilizes the mockup body 3 to pre-assemble four groups of roof support beams 1 into a square frame shape, and utilizes the rigid constraint provided by the mockup body 3 during the welding process of the roof support beam 1 and the main structure 2 of the vehicle body to effectively prevent the size change caused by the welding deformation of the roof support beam 1, reduce the influence of the welding deformation, and accurately ensure the positioning size of the overall flatness, diagonal line and mounting hole position of the welded roof support beam 1, realize the accurate matching of the roof 7 and the main structure 2 of the vehicle body, ensure that the 36 groups of bolt mounting holes 6 of the roof 7 and the roof support beam 1 are not deviated, and can be smoothly connected to realize the overall rapid and accurate installation of the roof 7, which is beneficial to improving the operation efficiency and reducing the operation cost.

[0063] In addition, the mockup device provided by the present application adopts a frame structure for the main body, and the mounting reference surface 33 is machined on the frame by machining, which not only has a simple overall structure and is convenient to operate, but also can be fixedly connected to the roof support beam 1 by using the mounting reference surface 33 to provide effective rigid constraint for the roof side beam 1 during the welding process, prevent the size change caused by the welding deformation, and further ensure the installation accuracy of the roof 7.

[0064] The above merely describes the preferred embodiments of the present application, and is not intended to limit the present application in any form. Although the present application has been disclosed with the preferred embodiments as above, it is not intended to limit the present application, and any person skilled in the art can make some changes or modifications to the above-mentioned technical content with the prompt as equivalent embodiments of equivalent changes without departing from the technical solution of the present application. Any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present application, which does not depart from the technical solution of the present application, still belongs to the scope of the present application.

Claims

1. A process for mounting rail vehicle bodies on the roof, characterized in that, The steps include: S1, fixing four roof support beams to the mounting reference surface of the template body with bolts to form a quadrilateral integral frame; the mounting reference surface of the template body has the same number of mounting holes as the roof support beams, and the overall flatness of the mounting reference surface is less than 2mm; S2. The pre-assembled roof support beam and the template body are placed into the main structure of the vehicle body. Multiple positioning seats protruding towards the center are set on the main structure of the vehicle body. The upper surface of the positioning seat is the positioning plane. During installation, the lower surface of the roof support beam is placed on the positioning plane of multiple positioning seats at the same time. S3. Weld the roof support beam to the main structure of the vehicle body and fix it. The template body is not removed during the welding process of the roof support beam. The template body rigidly constrains the roof support beam to prevent the positioning size of the roof support beam from shifting due to welding deformation. S4. After welding and cooling, remove the bolts between the main body of the template and the roof support beam, and remove the main body of the template from the roof support beam. S5. Lower the roof into the installed roof support beam and secure the roof to the roof support beam with bolts.

2. A template device for implementing the roof mounting process of a rail vehicle body as described in claim 1, characterized in that: It includes a template body and multiple template supports. The template body is supported on the template supports. The template body has a frame structure. Lifting lugs for connecting to lifting equipment are installed on the template body. The template body has an installation reference surface obtained by machining.

3. The template device according to claim 2, characterized in that: The template body is made of aluminum alloy profile.

4. A template device according to claim 2, characterized in that: The template body consists of two frames. The bottom surface of the lower frame is the installation reference surface, and the upper frame and the lower frame are fixedly connected by multiple connecting beams.

5. A template device according to claim 4, characterized in that: The width and length of the upper frame are smaller than the width and length of the lower frame, and the main body of the template is generally tapered, narrower at the top and wider at the bottom.

6. A template device according to claim 4, characterized in that: Both the upper and lower frames are constructed by splicing and welding together four side beams and multiple intermediate beams.

7. A template device according to any one of claims 2-6, characterized in that: The template support consists of a base plate, a support column, a support beam, and V-shaped support seats. The bottom of the support column is fixed to the base plate, the support beam is installed on the top of the support column, and multiple V-shaped support seats are installed on the support beam. The middle beam of the template body is supported in the V-shaped support seats.

8. A template device according to claim 7, characterized in that: The V-shaped support is formed by welding two metal plates diagonally upwards onto the support beam.

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