A lifting support device and lifting method for power unit components of EMU

Abstract

The present invention discloses a lifting support device and a lifting method for a power unit component of an EMU, and relates to the field of installation of a rail transit vehicle converter. The lifting support device comprises an insulating bidirectional support column, a bracket and a bracket fixing plate; the insulating bidirectional support column is cylindrical, with a metal column inside and an insulating casting outside, a metal stud is fixedly connected to the head end of the metal column, a hollow threaded hole is inside the tail end, and a nut is fixedly arranged; the bracket is in the shape of a rectangular plate, with a plurality of waist-shaped holes in the middle, and a waist-shaped hole is also opened at the left and right ends; the bracket fixing plate comprises a fixedly connected horizontal part and a vertical part, the bracket is connected to the bracket fixing plate through the bolt hole of the horizontal part, and its vertical part is installed on the power unit frame through two bolts. The present invention completes the lifting of the EMU power unit component by a corresponding method. The present invention can avoid the longitudinal pulling force of the busbar on the IGBT terminal, ensure the stability of the lifting structure, and better adapt to the lifting requirements of the EMU converter components.

Description

Technical Field

[0001] The invention relates to the field of rail transit vehicle converter installation, and in particular to a lifting support device and a lifting method for a power unit component of an EMU. Background Art

[0002] The rail transit vehicle inverter provides power and power for the vehicle system and is an important component of the rail transit vehicle. As the core component of the inverter, the power unit performs power conversion on the input voltage in the rail transit vehicle inverter and has also been widely used and developed rapidly. With the development and application of high-power semiconductor devices IGBT, the auxiliary power unit of rail transit vehicles is also developing in the direction of unitization and high reliability.

[0003] The inverter of rail transit EMU is hoisted at the bottom of the car. The inverter is opened for maintenance and repair on the left and right sides of the vehicle's travel direction. The left and right sides are convenient for maintenance and repair, but the space is limited. The remaining devices need to be hoisted at the bottom of the inverter. The hoisting must not only consider gravity and the longitudinal vibration of the vehicle during travel, but also the lateral force of acceleration and deceleration in the vehicle's forward direction. This puts higher requirements on the assembly safety and performance reliability of the hoisted and assembled devices and their internal components.

[0004] In the prior art, one installation method of the air-cooled power unit in the rail transit EMU inverter is vertical installation, that is, the air-cooled radiator is used as the structural support of the entire power unit at the bottom, and the IGBT, composite busbar and other components are assembled on it in sequence. However, this structure is only suitable for the application conditions of vertical assembly of locomotive inverters; for the requirements of EMU hoisting assembly, if the air-cooled heat dissipation power unit is turned upside down 180 degrees, the power device is easily damaged and electrically failed due to the gravity and vibration of the lower composite busbar and other components, and the requirements in terms of mechanical structure and electrical performance cannot be met.

[0005] In the prior art, there is another installation method for air-cooled power units in rail transit EMU inverters, which is a push-pull installation on the left and right sides of the vehicle's travel direction in the inverter. This position is on the left and right sides of the bottom of the EMU inverter, which is convenient for lid opening maintenance and repair, and is generally used to assemble components with high failure rates. The defects of this installation method are: ① It is mostly used for water-cooled heat dissipation power units. The power unit is vertically installed in the inverter side lid opening maintenance position and requires a large space; ② With the maturity of power unit control and protection technology, the auxiliary power unit has a low failure rate but still occupies a convenient maintenance position; ③ The push-pull power unit requires the power unit to be installed on the left and right sides of the vehicle's travel direction in the inverter. Under this limited condition, when the inverter is air-cooled, it is not conducive to the optimal layout design of the fan, air duct, and various heat dissipation components. Summary of the invention

[0006] The present invention solves the problem in the prior art that the traditional power unit is installed on both sides of the vehicle's travel direction in the converter, and solves the problems of structural instability, mechanical stress causing welding point cracking, IGBT device failure, and heat dissipation components not being optimally arranged during hoisting and assembly, and provides a lifting support device and a lifting method for the power unit components of an EMU.

[0007] The present invention is realized through the following technical scheme: a lifting and supporting device for power unit components of a motor vehicle, comprising an insulating bidirectional supporting column, a bracket and a bracket fixing plate; a plurality of insulating bidirectional supporting columns are provided; the insulating bidirectional supporting column is columnar, with a metal column inside and an insulating casting outside. These two features are for ensuring mechanical strength and insulation performance. A metal stud is fixedly connected to the head end of the metal column, a hollow threaded hole is inside the tail end of the metal column, and a nut is fixedly provided at the tail end. The metal stud and the hollow threaded hole are used for bidirectional connection for support. In order to increase the stress surface, the hollow threaded hole is used to fix the composite busbar to the insulating bidirectional supporting column by bolts. The metal stud is connected to the bottom of the radiator to increase the mechanical strength. In order to ensure the mechanical strength of the entire lifting structure while fixing the absorption capacitor, a bracket is installed at the bottom of the absorption capacitor to provide support. The bracket is in the shape of a rectangular plate, and a plurality of waist-shaped holes for fixing the absorption capacitor terminals are opened in the middle of the bracket. The waist-shaped hole design can avoid the problem of inappropriate assembly size caused by the processing error of the component itself and the assembly installation error; the left and right ends of the bracket are also each opened with a waist-shaped hole A, and the waist-shaped hole A is used to connect the bracket and the bracket fixing plate, so that the bracket is installed on the power unit frame through the bracket fixing plate. The bracket fixing plate includes a fixedly connected horizontal part and a vertical part, the horizontal part is provided with one to two bolt holes, and the vertical part is provided with two bolt holes. The bracket is connected to the bracket fixing plate through the bolt holes in the horizontal part, and the vertical part of the bracket fixing plate is installed on the power unit frame through two bolts.

[0008] Preferably, a double-bend connection structure is formed between the horizontal portion and the vertical portion of the bracket fixing plate.

[0009] A method for hoisting a power unit component of an EMU is provided. The hoisting method is implemented by using the above-mentioned component. The specific hoisting steps applicable to various installation environments are as follows:

[0010] ① First, select the installation point of the insulated bidirectional support column: select the installation point according to the center of gravity of the lifting component, and the total tension of each installation point ensures the longitudinal force balance of the composite busbar assembly; if the lifting component is a symmetrical structure, select the installation points symmetrically; if the lifting component is asymmetrical, determine its center of gravity through simulation, and select the installation point according to the center of gravity for lifting and fixing; the installation point must meet the product electrical clearance and creepage distance requirements at the same time;

[0011] ②Select the specifications and quantity of support columns: Determine the total force of all support columns according to the weight of the hoisting components. The number of support columns is selected based on the installation space conditions and the total force distribution based on the weight that a single bolt of a given specification can bear:

[0012] f×N=F N

[0013] f is the load bearing capacity of a single supporting column bolt;

[0014] N is the number of support columns;

[0015] F N is the total bearing capacity of all supporting columns; the total bearing capacity of supporting columns F N Greater than the total weight of the lifting components;

[0016] ③ Miniaturization design of the power unit. The design requirements are: maximize the use of existing space for the assembly of remaining components, and add additional components at the bottom of the hoisting components according to actual needs;

[0017] ④ Holes of the bracket: The number of holes is determined according to the terminals of the lifting components. Waist-shaped holes are used to avoid the problem of inappropriate assembly dimensions due to component processing errors and component installation errors;

[0018] ⑤Installation of bracket fixing plate: The bracket fixing plate is used to fix the bracket on the power unit frame, support the lifting components and avoid longitudinal force on the vehicle during operation;

[0019] ⑥ Pull up: In the power module hoisting structure, use the installation interval space to assemble the insulating bidirectional support column to pull up the composite busbar to prevent the composite busbar hoisted under the IGBT from being subjected to longitudinal mechanical stress due to gravity, resulting in deformation of the IGBT terminal and electrical failure;

[0020] ⑦ Support below: Use the bracket to lift the hoisting components, select the fixed points on the existing frame of the power unit and connect the bracket through the bracket fixing plate, and match the installation dimensions and mechanically strengthen the bracket fixing plate through the bending height, width and number of bending.

[0021] In the above steps, preferably, the bracket fixing plate increases strength through a double-bending structure, while adjusting the height and left-right spacing.

[0022] Compared with the prior art, the present invention has the following beneficial effects: the present invention provides a lifting support device and a lifting method for a power unit component of an EMU, which solves the following problems:

[0023] 1) When the power unit is hoisted and assembled, the busbar is installed under the IGBT. The use of a hoisting support device can avoid the longitudinal tension of the busbar on the IGBT terminal, and avoid the cracking of the IGBT terminal and DBC welding point due to mechanical stress, which in turn causes the IGBT device to fail;

[0024] 2) Select the support column installation point according to the center of gravity of the busbar to ensure uniform longitudinal force on the busbar and the stability of the lifting structure;

[0025] 3) While reducing the longitudinal stress of the IGBT, use the existing space to install the absorption capacitor to complete the IGBT shutdown overvoltage absorption;

[0026] 4) Assemble the composite busbar, absorption capacitor and other lifting components into one component to facilitate later disassembly and maintenance, thereby improving the maintainability of the power unit;

[0027] 5) The support column installed between the radiator and the busbar, together with the bracket under the absorption capacitor, forms a mechanical support structure that pulls up and supports down to ensure the stability of the lifting structure;

[0028] 6) The hoisting is not restricted by the installation position in the converter, which is convenient for the structural optimization design of the converter and is also conducive to the optimal layout design of the fan, air duct and various heat dissipation components in the converter;

[0029] 7) Breaking through the position limitation of the traditional power unit installed in the inverter on both sides of the vehicle travel direction, making the design of the entire inverter more flexible and better adapting to the lifting requirements of the inverter components of the EMU;

[0030] 8) The hoisting device and method can be used for the mechanical installation and fixation of other components in the converter, can be flexibly applied to the hoisting and assembly conditions of EMUs, and can also be applied to the assembly of hoisting components in other fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a structural schematic diagram of an insulating bidirectional support column.

[0032] Figure 2 A schematic diagram of the structure of the bracket.

[0033] Figure 3 It is a schematic diagram of the structure of the bracket fixing plate.

[0034] Figure 4 This is a schematic diagram of one angle of the lifting support for the power unit component.

[0035] Figure 5 This is another angle diagram of the lifting support of the power unit component.

[0036] The markings in the figure are as follows: 1-insulated bidirectional support column, 101-metal column, 102-insulated casting, 103-metal stud, 104-hollow threaded hole, 105-nut, 2-bracket, 201-waist-shaped hole, 202-waist-shaped hole A, 3-bracket fixing plate, 4-absorption capacitor, 5-bent composite busbar, 6-insulated bidirectional support column busbar fixing point. DETAILED DESCRIPTION

[0037] The present invention is further described below in conjunction with specific embodiments.

[0038] A lifting and supporting device for power unit components of a train set, such as Figure 1~Figure 3 As shown: it includes an insulating bidirectional support column 1, a bracket 2 and a bracket fixing plate 3; the insulating bidirectional support column 1 is provided with a plurality of them; the insulating bidirectional support column 1 is cylindrical, the interior is a metal column 101, the exterior of the metal column 101 is an insulating casting 102, the head end of the metal column 101 is fixedly connected with a metal stud 103, the rear end of the metal column 101 has a hollow threaded hole 104 inside, and a nut 105 is fixedly provided at the rear end; the bracket 2 is in the shape of a rectangular plate, and the middle part of the bracket 2 is opened A plurality of waist-shaped holes 201 for fixing the terminals of the absorption capacitor, and a waist-shaped hole A202 is also opened on the left and right ends of the bracket 2, and the waist-shaped hole A202 is used to connect the bracket 2 and the bracket fixing plate 3; the bracket fixing plate 3 includes a fixedly connected horizontal part and a vertical part, and the horizontal part is provided with one to two bolt holes, and the vertical part is provided with two bolt holes. The bracket 2 is connected to the bracket fixing plate 3 through the bolt holes of the horizontal part, and the vertical part of the bracket fixing plate 3 is installed on the power unit frame through two bolts.

[0039] In this embodiment, a preferred solution is adopted: a double-bending connection structure is formed between the horizontal portion and the vertical portion of the bracket fixing plate 3 .

[0040] A method for hoisting a power unit component of an EMU is provided. The hoisting method is implemented by using the above-mentioned hoisting support device. The following method is applicable to most hoisting environments. The specific hoisting steps are as follows:

[0041] ① First, select the installation point of the insulated bidirectional support column: select the installation point according to the center of gravity of the lifting component, and the total tension of each installation point ensures the longitudinal force balance of the composite busbar assembly; if the lifting component is a symmetrical structure, select the installation points symmetrically; if the lifting component is asymmetrical, determine its center of gravity through simulation, and select the installation point according to the center of gravity for lifting and fixing; the installation point must meet the product electrical clearance and creepage distance requirements at the same time;

[0042] ②Select the specifications and quantity of support columns: Determine the total force of all support columns according to the weight of the hoisting components. The number of support columns is selected based on the installation space conditions and the total force distribution based on the weight that a single bolt of a given specification can bear:

[0043] f×N=F N

[0044] f is the load bearing capacity of a single supporting column bolt;

[0045] N is the number of support columns;

[0046] F N is the total bearing capacity of all supporting columns; the total bearing capacity of supporting columns F N Greater than the total weight of the lifting components;

[0047] ③ Miniaturization design of the power unit. The design requirements are: maximize the use of existing space for the assembly of remaining components, and add additional components at the bottom of the hoisting components according to actual needs;

[0048] ④ Opening holes of bracket 2: The number of opening holes is determined according to the terminals of the lifting components. Waist-shaped holes are used to avoid the problem of inappropriate assembly dimensions due to component processing errors and component installation errors;

[0049] ⑤Installation of bracket fixing plate: The bracket fixing plate is used to fix the bracket on the power unit frame, support the lifting components and avoid longitudinal force on the vehicle during operation;

[0050] ⑥ Pull up: In the power module hoisting structure, use the installation interval space to assemble the insulating bidirectional support column to pull up the composite busbar to prevent the composite busbar hoisted under the IGBT from being subjected to longitudinal mechanical stress due to gravity, resulting in deformation of the IGBT terminal and electrical failure;

[0051] ⑦ Lower support: Use bracket 2 to lift the hoisting components, select fixed points on the existing frame of the power unit and connect bracket 2 through the bracket fixing plate, match the installation dimensions and mechanically strengthen the bracket fixing plate 3 through the bending height, width and number of bending. The bracket fixing plate 3 is double-bent to increase the strength, and the height and left-right spacing are adjusted at the same time.

[0052] In this embodiment, the bending composite busbar is hoisted when the structure is asymmetric. Figure 4 and Figure 5 As shown, the steps of hoisting method are as follows:

[0053] ① Assemble power devices including IGBT close to the heat sink;

[0054] ②Fix the four insulating bidirectional support columns to the radiator through one end of the bolts and the threaded holes on the surface of the radiator according to the torque. According to the center of gravity simulation results, the positions of the four insulating bidirectional support columns are determined to be overall backward on the radiator;

[0055] ③ Before assembling to the power unit, fix the three absorption capacitors on the composite busbar mounting holes. The absorption capacitors and the composite busbar together form a composite busbar assembly, which is convenient for later installation and maintenance;

[0056] ④The composite busbar assembly is assembled and fixed on the power device;

[0057] ⑤ The bolts pass through the composite busbar installation holes, then into the screw holes of the insulating bidirectional support columns and tighten according to the torque to fix the composite busbar and the insulating bidirectional support columns;

[0058] ⑥ Place the bracket 2 on the absorption capacitor, and pass the three terminals of the absorption capacitor through the waist-shaped hole. Do not tighten it temporarily to prevent errors from causing size matching problems in the subsequent connection between the bracket fixing plate 3 and the frame;

[0059] ⑦ Fix both sides of the bracket 2 to the power unit frame through the bracket fixing plate 3;

[0060] ⑧ Tighten the three waist-shaped holes in the middle of bracket 2 and the absorption capacitor terminals with nuts;

[0061] ⑨After assembling all the components of the power unit, turn it 180° so that the heat sink is on top, and hoist it into the converter.

[0062] The scope of protection claimed by the present invention is not limited to the above specific embodiments. For those skilled in the art, the present invention may have various deformations and changes. Any modifications, improvements and equivalent substitutions made within the concept and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for hoisting a power unit component of an EMU, characterized in that: The hoisting method is implemented by using components in a lifting support device for power unit components of an EMU; The EMU power unit component hoisting support device comprises an insulating bidirectional support column (1), a bracket (2) and a bracket fixing plate (3); the insulating bidirectional support column (1) is provided with a plurality of columns; the insulating bidirectional support column (1) is columnar, the interior of which is a metal column (101); the exterior of the metal column (101) is an insulating casting (102); the head end of the metal column (101) is fixedly connected with a metal stud (103); the rear end of the metal column (101) has a hollow threaded hole (104) inside, and a nut (105) is fixedly provided at the rear end; the bracket (2) is in the shape of a rectangular plate, and the middle of the bracket (2) is provided with a plurality of A waist-shaped hole (201) is provided for fixing the terminal of the absorption capacitor, and the left and right ends of the bracket (2) are each provided with a waist-shaped hole A (202), and the waist-shaped hole A (202) is used to connect the bracket (2) and the bracket fixing plate (3); the bracket fixing plate (3) comprises a horizontal portion and a vertical portion which are fixedly connected, the horizontal portion is provided with one to two bolt holes, and the vertical portion is provided with two bolt holes, the bracket (2) is connected to the bracket fixing plate (3) through the bolt holes in the horizontal portion, and the vertical portion of the bracket fixing plate (3) is installed on the power unit frame through two bolts; the horizontal portion and the vertical portion of the bracket fixing plate (3) are connected in a double-bend structure; The specific lifting steps are as follows: ① First, select the installation point of the insulated bidirectional support column: select the installation point according to the center of gravity of the lifting component, and the total tension of each installation point ensures the longitudinal force balance of the composite busbar assembly; if the lifting component is a symmetrical structure, select the installation points symmetrically; if the lifting component is asymmetrical, determine its center of gravity through simulation, and select the installation point according to the center of gravity for lifting and fixing; the installation point must meet the product electrical clearance and creepage distance requirements at the same time; ②Select the specifications and quantity of support columns: Determine the total force of all support columns according to the weight of the hoisting components. The number of support columns is selected based on the installation space conditions and the total force distribution based on the weight that a single bolt of a given specification can bear: f×N=F N f is the load bearing capacity of a single supporting column bolt; N is the number of support columns; F N is the total bearing capacity of all supporting columns; the total bearing capacity of supporting columns F N Greater than the total weight of the lifting components; ③ Miniaturization design of the power unit. The design requirements are: maximize the use of existing space for the assembly of remaining components, and add additional components at the bottom of the hoisting components according to actual needs; ④ Holes of the bracket (2): The number of holes is determined according to the terminals of the lifting components. Waist-shaped holes are used to avoid problems with inappropriate assembly dimensions due to component processing errors and component installation errors; ⑤Installation of bracket fixing plate: The bracket fixing plate is used to fix the bracket on the power unit frame, support the lifting components and avoid longitudinal force on the vehicle during operation; ⑥ Pull up: In the power module hoisting structure, use the installation interval space to assemble the insulating bidirectional support column to pull up the composite busbar to prevent the composite busbar hoisted under the IGBT from being subjected to longitudinal mechanical stress due to gravity, resulting in deformation of the IGBT terminal and electrical failure; ⑦ Supporting below: Use the bracket (2) to support the hoisting component, select a fixing point on the existing frame of the power unit, connect the bracket (2) through the bracket fixing plate, and match the installation dimensions and mechanically strengthen the bracket fixing plate according to the bending height, width and number of bendings; In addition, when the bent composite busbar structure is asymmetric, the hoisting method and steps are as follows: ① Assemble power devices including IGBT close to the heat sink; ②Fix the four insulating bidirectional support columns to the radiator through one end of the bolts and the threaded holes on the surface of the radiator according to the torque. According to the center of gravity simulation results, the positions of the four insulating bidirectional support columns are determined to be overall backward on the radiator; ③ Before assembling to the power unit, fix the three absorption capacitors on the composite busbar mounting holes. The absorption capacitors and the composite busbar together form a composite busbar assembly; ④The composite busbar assembly is assembled and fixed on the power device; ⑤ The bolts pass through the composite busbar installation holes, then into the screw holes of the insulating bidirectional support columns and tighten according to the torque to fix the composite busbar and the insulating bidirectional support columns; ⑥ Place the bracket (2) on the absorption capacitor, and pass the three terminals of the absorption capacitor through the waist-shaped hole. Do not tighten them yet to prevent errors from causing size matching problems when the bracket fixing plate (3) is connected to the frame; ⑦ Fix both sides of the bracket (2) to the power unit frame through the bracket fixing plate (3); ⑧ Tighten the three waist-shaped holes in the middle of the bracket (2) and the terminals of the absorption capacitor with nuts; ⑨After assembling all the components of the power unit, turn it 180° so that the heat sink is on top, and hoist it into the converter.

2. A method for hoisting a power unit component of an EMU according to claim 1, characterized in that: The bracket fixing plate (3) has a double-bending structure to increase strength and adjust the height and left-right spacing at the same time.

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