Multi-door side wall reverse prefabricated deflection processing method

Abstract

The application discloses a side wall reverse prefabricated deflection processing method of multiple doorways, and mainly comprises the following steps: S1, during side wall processing, taking a bottom straight line as a positioning reference, and processing each doorway according to an irregular quadrilateral; S2, calculating each doorway compensation, and the calculation method of the doorway compensation comprises the following steps: S201, dividing the side wall into blocks from the center of the vehicle body to the edge of each doorway; S202, sequentially calculating the theoretical deflection value of the edge of each doorway; S203, sequentially calculating the rotation angle alpha of each block, and calculating the doorway width compensation. The reverse prefabricated deflection processing method is suitable for both "block side wall processing-reassembly welding" and "pre-fabricated deflection similar to an omega shape-reassembly welding-assembly in a straight line in a processing tool-last overall processing". The deflection prefabrication of the side wall single component is realized in the straight line reference state, thereby reducing the difficulty of the vehicle body prefabricated deflection in the subsequent process, and guaranteeing the manufacture of the large deflection vehicle body.

Description

Technical Field

[0001] This invention relates to the field of side wall processing technology for urban rail passenger cars, and in particular to a method for processing the prefabricated deflection of side walls with multiple doors. Background Technology

[0002] Urban rail passenger cars are mainly used in city subways and light rail systems. To facilitate the boarding and alighting of more passengers at the same time, the cars are typically equipped with multiple doors, usually 4 to 5 doors. Due to the large load on urban rail vehicles, it is necessary to retain a large deflection after the car body is manufactured. The deflection of the side walls is the main factor affecting the final deflection dimension of the car body in the height direction.

[0003] The main body of the urban rail car is segmented side walls, and a small number of them use integral side walls. However, due to the height requirements of the doorway, the steel structure profiles at the connection between the upper part of the integral side wall and the roof are less retained, which is not conducive to the overall prefabrication deflection of the side wall, resulting in weak strength. Even if the prefabrication deflection is large, the rebound is also large.

[0004] The existing manufacturing method involves welding the side walls as individual pieces without pre-fabricating the deflection. During the assembly and welding of the vehicle body, the large deflection is pre-fabricated on the underframe. This method results in a large deflection rebound after the vehicle body is assembled, with a large rebound range and no regularity. Especially for the whole vehicle with a deflection greater than 11mm, the deflection manufacturing control is extremely difficult, and the diagonal deformation of each door is also large, making it difficult to guarantee the consistency of quality.

[0005] Therefore, based on the above-mentioned technical problems, those skilled in the art urgently need to develop a method for processing the prefabricated deflection of the sidewalls of multi-door structures. Summary of the Invention

[0006] The purpose of this invention is to provide a method that calculates the reverse deviation of the doorway size based on the position of the doorway in the vehicle body layout, realizes doorway width compensation processing, and synthesizes the doorway width according to the theoretical size so that the side wall has its own prefabricated deflection. This shifts the size control of the overall vehicle deflection to the side wall synthesis process, reduces the deflection springback after vehicle body synthesis, reduces welding deformation, and improves the manufacturing quality of vehicle body deflection to better realize the manufacturing of large deflection vehicle bodies.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] The present invention provides a method for processing the prefabricated deflection of side walls with multiple doorways, the method mainly comprising the following steps:

[0009] S1. When processing the side walls, use the bottom straight line as the positioning reference, and process each doorway according to an irregular quadrilateral.

[0010] S2. Calculate the compensation for each entrance. The calculation method for entrance compensation includes the following steps:

[0011] S201. Divide the side wall into sections from the center of the vehicle body to the edge of each doorway;

[0012] S202. Calculate the theoretical deflection value for each doorway edge in sequence:

[0013] Setting: R 2 =L 2 +(R-h_max) 2 ;

[0014] We get: R = (L) 2 +h_max 2 ) / 2h_max;

[0015]

[0016] In the formula:

[0017] R is the radius of curvature of the pre-fabricated arc;

[0018] L is the distance from the center of the bolster beam to the center of the vehicle body;

[0019] h_max — Maximum deflection value;

[0020] h is the deflection value at any point;

[0021] X represents the distance from the edge of any doorway to the center of the vehicle body;

[0022] S203. Calculate the rotation angle α of each block in sequence, and calculate the doorway width compensation.

[0023] Furthermore, in step S203, the calculation of the doorway width compensation is based on the following algorithm:

[0024] Δh=|h n+1 -h n |;

[0025] α = arcsin(Δh / a);

[0026] d = b * tanα;

[0027] d1=b*tan(arcsin(|y1-h_max| / X1));

[0028] d2=b*tan(arcsin(|y3-y2| / (X3-X2)));

[0029] d4=b*tan(arcsin(|y4-y3| / (X4-X3)));

[0030] d3 = d2 - d1 - d4;

[0031] In the formula:

[0032] α is the rotation angle of the corresponding block;

[0033] Δh is the deflection difference between two adjacent selected points;

[0034] 'a' represents the horizontal distance between the two edges of the block;

[0035] y1, y2, y3, and y4 are the deflection values ​​at the corresponding points;

[0036] X1 is the distance from the center of the vehicle body to the edge of the first doorway;

[0037] X2 is the distance from the center of the vehicle body to the edge of the second doorway;

[0038] X3 is the distance from the center of the vehicle body to the edge of the third doorway;

[0039] X4 is the distance from the center of the vehicle body to the edge of the fourth doorway;

[0040] b is the height of the doorway;

[0041] d is the doorway width compensation value;

[0042] d1, d2, d3, and d4 are the width compensation values ​​for the corresponding points at the doorway;

[0043] Furthermore, the deflection changes at the center of the vehicle body Δh1 and the ends of the vehicle body tend to be gradual, and compensation in the same direction as the deflection changes is used at d1 and d4.

[0044] The lower edge of the doorway should be controlled according to the following dimensions:

[0045] X1' = X1 - d1;

[0046] X4' = X4 - d4;

[0047] The deflection changes at the other doorways tend to be steeper, and compensation is applied at d2 and d3 in the opposite direction to the deflection changes;

[0048] The lower edge of the doorway should be controlled according to the following dimensions:

[0049] X2' = X2 + d2 - d1;

[0050] X3'=X3+d3=X3+d2-d1-d4.

[0051] In the above technical solution, the present invention provides a method for processing the prefabricated deflection of the sidewalls of multi-door structures, which has the following beneficial effects:

[0052] The reverse prefabrication deflection processing method of the present invention is applicable to both "segmented sidewall processing - reassembly and welding" and "prefabrication of deflection into an Ω-shaped assembly - straight clamping in a processing fixture - overall processing". It achieves deflection prefabrication of individual sidewall components under a straight reference state, thereby reducing the difficulty of prefabricating the deflection of the vehicle body in subsequent processes and providing a guarantee for the manufacturing of large-deflection vehicle bodies.

[0053] The anti-pre-fabricated deflection processing method of the present invention uses a straight line as the processing reference, which unifies the side wall processing positioning reference and reduces the influence of deflection changes on the position dimension error. Attached Figure Description

[0054] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0055] Figure 1 A schematic diagram of the sidewall structure of a method for processing the prefabricated deflection of sidewalls with multiple doorways provided in this embodiment of the invention;

[0056] Figure 2 This invention provides a schematic diagram of a method for processing the sidewalls of multi-door structures with prefabricated deflection, where the doorway is processed into an irregular quadrilateral.

[0057] Figure 3 A schematic diagram of the self-forming structure of the sidewall deflection in a method for processing the prefabricated deflection of sidewalls with multiple doorways provided in this embodiment of the invention;

[0058] Figure 4 This invention provides a schematic diagram of a method for processing the prefabricated deflection of side walls with multiple doorways, showing the process from the center of the vehicle body to the edge of each doorway.

[0059] Figure 5 A schematic diagram illustrating the calculation of the theoretical deflection value of each doorway edge in a method for processing the prefabricated deflection of sidewalls with multiple doorways provided in this embodiment of the invention;

[0060] Figure 6 This invention provides a schematic diagram of the calculation of doorway width compensation in a method for processing the prefabricated deflection of sidewalls with multiple doorways. Figure 1 ;

[0061] Figure 7 This invention provides a schematic diagram of the calculation of doorway width compensation in a method for processing the prefabricated deflection of sidewalls with multiple doorways. Figure 2 ;

[0062] Explanation of reference numerals in the attached figures:

[0063] 101. First block; 102. Second block; 103. Third block. Detailed Implementation

[0064] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0065] See Figures 1 to 7 As shown;

[0066] This embodiment provides a method for processing the prefabricated deflection of side walls with multiple doorways. The processing method mainly includes the following steps:

[0067] S1. When processing the side walls, use the bottom straight line as the positioning reference, and process each doorway according to an irregular quadrilateral.

[0068] S2. Calculate the compensation for each entrance. The calculation method for entrance compensation includes the following steps:

[0069] S201, see also Figure 4 As shown, the side walls are divided into sections from the center of the vehicle body to the edge of each doorway;

[0070] S202, see also Figure 5 As shown, the theoretical deflection value for each doorway edge is calculated sequentially:

[0071] Setting: R 2 =L 2 +(R-h_max) 2 ;

[0072] We get: R = (L) 2 +h_max 2 ) / 2h_max;

[0073]

[0074] In the formula:

[0075] R is the radius of curvature of the pre-fabricated arc;

[0076] L is the distance from the center of the bolster beam to the center of the vehicle body;

[0077] h_max — Maximum deflection value;

[0078] h is the deflection value at any point;

[0079] X represents the distance from the edge of any doorway to the center of the vehicle body;

[0080] S203. Calculate the rotation angle α of each block in sequence, and calculate the doorway width compensation.

[0081] Preferably, in step S203 above, the calculation of the doorway width compensation is based on the following algorithm:

[0082] Δh=|h n+1 -h n |;

[0083] α = arcsin(Δh / a);

[0084] d = b * tanα;

[0085] d1=b*tan(arcsin(|y1-h_max| / X1));

[0086] d2=b*tan(arcsin(|y3-y2| / (X3-X2)));

[0087] d4=b*tan(arcsin(|y4-y3| / (X4-X3)));

[0088] d3 = d2 - d1 - d4;

[0089] In the formula:

[0090] α is the rotation angle of the corresponding block;

[0091] Δh is the deflection difference between two adjacent selected points;

[0092] 'a' represents the horizontal distance between the two edges of the block;

[0093] y1, y2, y3, and y4 are the deflection values ​​at the corresponding points;

[0094] X1 is the distance from the center of the vehicle body to the edge of the first doorway;

[0095] X2 is the distance from the center of the vehicle body to the edge of the second doorway;

[0096] X3 is the distance from the center of the vehicle body to the edge of the third doorway;

[0097] X4 is the distance from the center of the vehicle body to the edge of the fourth doorway;

[0098] b is the height of the doorway;

[0099] d is the doorway width compensation value;

[0100] d1, d2, d3, and d4 are the width compensation values ​​for the corresponding points at the doorway;

[0101] The deflection changes at the center of the vehicle body Δh1 and the ends of the vehicle body tend to be gradual, and compensation in the same direction as the deflection changes is used at d1 and d4.

[0102] The lower edge of the doorway should be controlled according to the following dimensions:

[0103] X1' = X1 - d1;

[0104] X4' = X4 - d4;

[0105] The deflection changes at the other doorways tend to be steeper, and compensation is applied at d2 and d3 in the opposite direction to the deflection changes;

[0106] The lower edge of the doorway should be controlled according to the following dimensions:

[0107] X2' = X2 + d2 - d1;

[0108] X3'=X3+d3=X3+d2-d1-d4.

[0109] In this embodiment, taking a vehicle body with 5 doors as an example, the middle door is located at the center X0 of the vehicle body. The door compensation adopts the compensation in the opposite direction to the deflection change, that is: X0'=X0+d0, where point d0 is located outside the door.

[0110] The side wall is divided into sections from the center of the vehicle body to the edge of each doorway, namely the first section, the second section, and the third section from the center of the vehicle body to the end of the vehicle body;

[0111] Setting: R 2 =L 2 +(R-h_max) 2 ;

[0112] We get: R = (L) 2 +h_max 2 ) / 2h_max;

[0113]

[0114] In the formula:

[0115] R is the radius of curvature of the pre-fabricated arc;

[0116] L is the distance from the center of the bolster beam to the center of the vehicle body;

[0117] h_max — Maximum deflection value;

[0118] h is the deflection value at any point;

[0119] X represents the distance from the edge of any doorway to the center of the vehicle body;

[0120] The curvature radius R of the precast arc and the deflection h at any point can be obtained by calculating using the above formula.

[0121] Calculate the rotation angle α for each segment again, and calculate the doorway width compensation:

[0122] Based on the above calculation method, let Δh = |hn+1 -h n |;

[0123] See Figure 6 , Figure 7 As shown, we obtain: Δh2=|y3-y2|;

[0124] α = arcsin(Δh / a);

[0125] d = b * tanα;

[0126] d1=b*tan(arcsin(|y1-h_max| / X1));

[0127] d2=b*tan(arcsin(|y3-y2| / (X3-X2)));

[0128] d4=b*tan(arcsin(|y4-y3| / (X4-X3)));

[0129] d3 = d2 - d1 - d4;

[0130] In the above technical solution, the present invention provides a method for processing the prefabricated deflection of the sidewalls of multi-door structures, which has the following beneficial effects:

[0131] The reverse prefabrication deflection processing method of the present invention is applicable to both "segmented sidewall processing - re-welding assembly" and "prefabrication of deflection into an Ω-shaped form for assembly and welding - straight-line clamping in a processing fixture - final overall processing". It achieves deflection prefabrication of single sidewall components under a straight-line reference state, thereby reducing the difficulty of prefabricating deflection in subsequent vehicle body processes and providing a guarantee for the manufacturing of large-deflection vehicle bodies.

[0132] The anti-pre-fabricated deflection processing method of the present invention uses a straight line as the processing reference, which unifies the side wall processing positioning reference and reduces the influence of deflection changes on the position dimension error.

[0133] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A multi-portal side wall reverse precast deflection processing method, characterized in that, The processing method mainly comprises the following steps: S1, when the side wall is processed, taking the bottom straight line as the positioning reference, each door opening is processed according to an irregular quadrilateral; S2, calculating the compensation of each door opening, the calculation method of the door opening compensation comprises the following steps: S201, dividing the side wall into blocks from the center of the vehicle body to the edge of each door opening in turn; S202, calculating the theoretical deflection value of the edge of each door opening in turn: Set: ; Obtained: ; ； In the formula: R is the radius of curvature of the prefabricated arc line; L is the distance from the center of the bolster to the center of the vehicle body; h_max is the maximum deflection value; h is the deflection value of any point; X is the distance from any door opening edge to the center of the vehicle body; S203, calculating the rotation angle a of each block in turn, and calculating the door opening width compensation based on the following algorithm: Δh = |h n+1 -h n |; a = arcsin (Δh / a); d = b*tan a; d1 = b*tan (arcsin (|y1-h_max| / X1)); d2 = b*tan (arcsin (|y3-y2| / (X3-X2))); d4 = b*tan (arcsin (|y4-y3| / (X4-X3))); d3 = d2-d1-d4; In the formula: a is the rotation angle of the corresponding block; Δh is the deflection difference between the adjacent two selected points; a is the horizontal distance between the two edges of the block; y1, y2, y3, y4 are the deflection values of the corresponding points; X1 is the distance from the center of the vehicle body to the first door opening edge; X2 is the distance from the center of the vehicle body to the second door opening edge; X3 is the distance from the center of the vehicle body to the third door opening edge; X4 is the distance from the center of the vehicle body to the fourth door opening edge; b is the door opening height; d is the door opening width compensation value; d1, d2, d3, d4 are the door opening corresponding point width compensation values.

2. The method of claim 1, wherein, Δh1 at the center of the vehicle body and the deflection change at the end of the vehicle body tend to be gentle, and d1 and d4 are compensated in the same direction as the deflection change; The lower edge of the door opening at this place is controlled according to the following size: X1'=X1-d1; X4'=X4-d4; The deflection change at the rest of the door openings tends to be steep, and d2 and d3 are compensated in the opposite direction of the deflection change; The lower edge of the door opening at this place is controlled according to the following size: X2'=X2+d2-d1; X3'=X3+d3=X3+d2-d1-d4.

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