Manufacturing method of integrated laminated spring

Abstract

The present invention provides a method for manufacturing an integrated laminated spring, wherein the rubber pad top plate and the stopper base are designed as an integrated structure, and the rubber pad mold and the stopper mold are designed as an integral mold; the rubber pad bottom plate, the rubber pad rubber iron piece, the rubber pad top plate and the stopper base integrated structure, the stopper rubber iron piece, and the stopper top plate are placed in the integral mold, and rubber is injected into the integral mold to make the rubber pad and the stopper become one. The rubber passes through the rubber pad cavity through the rubber pad top plate, the stopper base, and the stopper cavity in sequence, and the rubber pad bottom plate, the rubber pad, the rubber pad top plate, the stopper base as a whole, the stopper cavity, and the stopper top plate are vulcanized into one, i.e., an integral laminated spring without fasteners. The stopper rubber profile is set to a straight line and the stopper top mold insert installation part is set to an arc shape inclined outward, so as to optimize the structure of the laminated spring, facilitate demoulding, and do not damage the rubber during the mold opening process, thereby ensuring product quality.

Description

Technical Field

[0001] The present invention relates to the technical field of EMU bogie suspension systems, and more particularly to a method for manufacturing an integrated laminated spring. Background Art

[0002] my country boasts the world's longest high-speed rail network, reaching nearly 40,000 kilometers by the end of 2020, creating the world's most developed high-speed rail network. High-speed rail has made travel more convenient and efficient for Chinese citizens, and has also reduced freight transport times. This has significantly contributed to my country's economic development and social progress, and is a hallmark of the country's modernization. However, my country's high-speed rail system is not expected to remain at its current level; it continues to rapidly develop. The Fuxing bullet train, developed by China Railway Corporation with fully independent intellectual property rights and world-leading standards, is currently the world's fastest operating high-speed train. Fuxing bullet trains currently have three speed ratings: CR400 / 300 / 200, with the numbers representing maximum speed and corresponding to sustained speeds of 350, 250, and 160 km / h, respectively. They are suitable for high-speed rail (HSR), rapid rail (RRT), and intercity rail (CRT). my country is currently developing a new generation of even higher-speed EMUs, and high-speed rail exceeding 400 km / h will become a reality in the near future. Developing new Fuxing trains that are faster, safer, more environmentally friendly, more energy-efficient, and more intelligent will propel my country's high-speed rail industry from a leading position to a technological leader. However, increasing railway speeds isn't simply about running trains faster; higher speeds place greater demands on various components. The first consideration is whether the car's bogies can meet the expected speed requirements.

[0003] The laminated spring in the external bogie suspension of high-speed EMU is used to attenuate and isolate the vibration from the axle box, and plays the role of supporting and protecting the steel spring. It is installed at the bottom of the primary steel spring (such as Figure 1 shown), Figure 1 In the figure, 12 is a laminated spring, 13 is a vertical hard stop for the train, 14 is an axial vertical hard stop, and 15 is a steel spring. During normal vehicle operation, only the bottom rubber pad of the laminated spring operates, bearing vertical loads and reducing and isolating vibrations. The upper stop is unloaded. Under heavy or extreme loads, the vertical hard stop for the train contacts the vertical hard stop for the axlebox, achieving vertical limiting. At this point, the upper stop acts as a supplementary buffer.

[0004] like Figure 2As shown, the laminated spring includes a rubber pad and a stopper. The rubber pad includes a rubber pad rubber 1, a rubber pad bottom plate 2 and a rubber pad top plate 3. The stopper includes a stopper base 4, a stopper rubber 5 and a stopper top plate 6. The rubber pad top plate includes a boss 10 located on the outer circumference of the stopper. The boss 10 is used to limit the rigid spring. The boss 10 has a drainage groove 11a for drainage. The rubber pad rubber 1 and the stopper rubber 5 of the rubber pad are both made of metal and rubber laminated together. The existing laminated spring is an assembled structure. After the vulcanization and surface treatment of the rubber pad and the stopper are completed separately, they are assembled by screws to form a finished product. During production, the rubber pad and the stopper are vulcanized separately through separate molds, and the components are relatively large. The process flow is complicated and the production control cost is high. In addition, the rubber pad and the stopper are connected by screws, which poses a risk of screw loosening. Summary of the Invention

[0005] The purpose of the present invention is to provide a manufacturing method for an integrated laminated spring, reduce the number of parts of the laminated spring, simplify the process flow, reduce process turnover, thereby improving the quality of the laminated spring and making the laminated spring meet the quality requirements of higher-speed EMUs.

[0006] The purpose of the present invention is mainly achieved through the following technical solutions:

[0007] The manufacturing method of the integrated laminated spring is as follows: the rubber pad top plate and the stop base are designed as an integrated structure, and the rubber pad mold and the stop mold are designed as an integral mold; the rubber pad bottom plate, the rubber pad rubber iron piece, the rubber pad top plate and the stop base integrated structure, the stop rubber iron piece, and the stop top plate are placed in the integral mold, and rubber is injected into the integral mold to make the rubber pad and the stop become one.

[0008] The rubber pad top plate and the base are designed to be an integrated structure:

[0009] 1. Only one set of molds is needed for vulcanization to form a laminated spring product in one step without the need for assembly.

[0010] 2. The fastener connection between the rubber pad top plate and the base has been cancelled, eliminating the risk of screw loosening and improving product reliability.

[0011] 3. The laminated spring is formed into an integrated structure through glue injection and vulcanization. The process is simple, which reduces the process flow, avoids the collision during the transportation of parts, and ensures product quality.

[0012] 4. The rubber pad and the stopper are integrated as a whole, eliminating the assembly process, ensuring the coaxiality of the rubber pad and the stopper, greatly reducing the position deviation of the upper and lower mounting surfaces of the laminated spring, and facilitating installation.

[0013] Furthermore, a rubber flow channel is provided which passes through the rubber pad cavity, the rubber pad top plate, the stop base and the stop cavity; during vulcanization, rubber is injected into the rubber pad cavity, and the rubber enters the stop cavity from the rubber pad cavity through the rubber flow channel, thereby completing integrated rubber injection vulcanization.

[0014] The rubber pad and stopper described in the present invention, although they can eventually form an integrated laminated spring through vulcanization due to the integration of the rubber pad top plate and the stopper base, the rubber pad part and the stopper part can be injected separately during the injection of glue. The present invention uses the same rubber material, and only one injection of glue is required. When manufacturing a laminated spring according to the method described in the present invention, the rubber pad top plate and the stopper base are an integrated structure. After all the components are placed in the mold, they are vulcanized by injection of glue, and a finished laminated spring can be formed by one vulcanization. The rubber material sequentially passes from the rubber pad cavity through the rubber pad top plate, the stopper base and the stopper cavity, and vulcanizes the rubber pad bottom plate, rubber pad, rubber pad top plate stopper base as a whole, the stopper cavity and the stopper top plate into one, i.e., an integrated laminated spring without fasteners. Similarly, the rubber material can also be injected from the stopper cavity and enter the rubber pad cavity through the stopper cavity.

[0015] Furthermore, the rubber material is natural rubber, chloroprene rubber or isoprene rubber.

[0016] Furthermore, the number of the rubber flow channels is 2, and the diameter of the rubber flow channels is greater than 1 mm. The diameter of the rubber flow channels is greater than 1 mm, so that the rubber material can smoothly flow into the rubber pad cavity and the stopper cavity.

[0017] Furthermore, the thickness of the stopper rubber profile is increased to match the strength of the stopper and the rubber pad so that the stopper rubber and the rubber pad rubber use the same rubber material.

[0018] Furthermore, the stop rubber profile is set to be linear and flush with the stop top plate, so that when demoulding, the mold of the stop part is demoulded upwards.

[0019] The stop rubber profile of the prior art is a profile that is concave in the direction of the center line. The stop rubber profile is concave because the stop and the rubber pad are not a whole, so demolding can be done in both directions. The laminated spring of the present invention is an integrated structure. The rubber pad top plate and the stop base are integrated. The rubber pad top plate has a boss, which will be blocked by the boss when demolding in both directions and cannot be demolded. Therefore, the stop rubber profile is set to be linear, and the demolding is upward. Under the premise of ensuring the release of rubber stress, it is beneficial to product production and demolding, and high-quality batch production is achieved. Since the stop rubber profile is linear, the volume of the stop rubber increases, and the strength of the stop rubber increases. The use of the same rubber material for the stop rubber and the rubber pad rubber can ensure the strength of the integrated laminated spring.

[0020] Furthermore, the mold insert installation portion of the stopper top is configured as an arc shape that is beneficial for product production out of the mold.

[0021] Furthermore, the installation portion of the mold insert at the top of the stopper is in the shape of an arc inclined outward.

[0022] The present invention has the following beneficial effects:

[0023] The manufacturing method for an integrated laminated spring described herein places the rubber pad and stopper in a single mold, using only one set of molds. Vulcanization is completed in a single step. After vulcanization, the rubber pad and stopper do not need to be reassembled. This reduces the number of component parts in the laminated spring and significantly reduces positional deviations between the upper and lower mounting surfaces of the laminated spring, ensuring product quality, significantly reducing rework rates, and lowering production costs. The rubber pad and stopper are integrated, eliminating the need for fasteners and the risk of loose screws. The laminated spring's structure is optimized for ease of demolding, preventing damage to the rubber during mold opening, and ensuring product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings, which constitute part of this application, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an undue limitation of the present invention. In the accompanying drawings:

[0025] Figure 1 This is a diagram of the installation position of the laminated spring.

[0026] Figure 2 It is a schematic diagram of the laminated spring structure of the prior art.

[0027] Figure 3 It is a schematic diagram of the integrated laminated spring structure of Example 1.

[0028] Rubber pad rubber 1, rubber pad bottom plate 2, rubber pad top plate 3, stop base 4, stop rubber 5, Figure 2 Stop rubber profile 51a, Figure 3 Stop rubber profile 51b, stop top plate 6, rubber flow channel 7, Figure 2 Stop the top mold insert installation part 8a, Figure 3 The stopper top mold insert installation part 8b, screw 9, boss 10, drainage groove 11a, laminated spring 12, train vertical hard stop 13, axial vertical hard stop 14, steel spring 15. DETAILED DESCRIPTION

[0029] The embodiments of the present invention are described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered by the claims. Example 1

[0030] like Figure 2 As shown, the laminated spring of the prior art includes two independent parts: a rubber pad and a stopper.

[0031] The rubber pad includes a rubber pad bottom plate 2, a rubber pad rubber 1 and a rubber pad top plate 3 from bottom to top.

[0032] The stopper includes a stopper base 4 , a stopper rubber 5 and a stopper top plate 6 from bottom to top.

[0033] The rubber pad 1 and the stopper rubber 5 are both made of metal iron and rubber laminated together. The rubber pad top plate 3 and the stopper base 4 are connected by fasteners to form a laminated spring. During vulcanization, the metal iron is placed in the mold, and after the rubber is injected, the rubber and the iron are bonded to form an integral component.

[0034] Existing laminated springs consist of two separate components, a rubber pad and a stopper, known as an assembled structure. The rubber pad and stopper must be vulcanized and surface-treated separately before being assembled with screws to form the finished product. During production, the rubber pad and stopper are vulcanized in separate molds, resulting in a complex process flow and high production control costs. Furthermore, the rubber pad and stopper are connected by screws, which poses a risk of loosening.

[0035] The present invention aims to avoid the shortcomings of the prior art, improve the quality of the laminated spring, and make the laminated spring adaptable to the bogie requirements of higher-speed EMUs, such as Figure 2 and Figure 3 As shown, this embodiment integrates the two metal parts of the rubber pad top plate 3 and the stop base 4 into an integrated design. After vulcanization, the laminated spring is formed into a single integral part, improving the quality of the laminated spring and increasing production efficiency. The integrated laminated spring of this application includes, from bottom to top, the rubber pad bottom plate 2, the rubber pad rubber 1, the rubber pad top plate stop base as a whole, the stop rubber 5, and the stop top plate 6, which are integrally formed through a single vulcanization.

[0036] The specific manufacturing method of the integrated laminated spring is as follows:

[0037] The rubber pad top plate 3 and the stop base 4 are designed as an integrated structure, and the rubber pad mold and the stop mold are designed as an integral mold; the rubber pad bottom plate 2, the rubber pad rubber pad rubber 1 iron piece, the rubber pad top plate and the stop base integrated structure, the stop rubber 5 iron piece, and the stop top plate 6 are placed into the integral mold, and rubber is injected into the integral mold to make the rubber pad and the stop become one.

[0038] like Figure 3 As shown, a rubber flow channel 7 is provided which passes through the rubber pad cavity, the rubber pad top plate 3, the stopper base 4 and the stopper cavity; during vulcanization, rubber is injected into the rubber pad cavity, and the rubber enters the stopper cavity from the rubber pad cavity through the rubber flow channel 7, completing the integrated injection vulcanization.

[0039] The rubber material is natural rubber.

[0040] There are two rubber flow channels 7 symmetrically distributed on both sides of the central axis of the laminated spring. The diameter of the rubber flow channels 7 is greater than 1 mm.

[0041] like Figure 3 As shown, the stop rubber profile is set to be linear and flush with the stop top plate 6. When demoulding, the mold of the stop part is demoulded upward.

[0042] The installation part of the stopper top mold insert 8b is an arc shape inclined toward the outside.

[0043] Through the above configuration, the integrated laminated spring is integrally molded using the same rubber material. A rubber flow channel 7 is provided, extending through the rubber pad cavity, rubber pad top plate 3, stopper base 4, and stopper cavity. The rubber material flows sequentially from the rubber pad cavity through the rubber pad top plate 3, stopper base 4, and stopper cavity, vulcanizing the rubber pad bottom plate 2, rubber pad rubber 1, the entire rubber pad top plate stopper base, the stopper cavity, and the stopper top plate 6 into a single, integrated, fastener-free laminated spring. To facilitate demolding, the structure of the laminated spring is optimized, including designing the stopper rubber profile as a straight line and designing the stopper top mold insert mounting area as an outwardly inclined arc.

[0044] The laminated spring described in this embodiment is formed into an integrated structure through integrated injection molding and vulcanization. This simplifies the process, reduces process flow, avoids bumps and collisions during component handling, and ensures product quality. The rubber pad and stopper are integrated into a single unit, eliminating the assembly process and ensuring coaxiality between the rubber pad and stopper. This significantly reduces positional deviation between the upper and lower mounting surfaces of the laminated spring, facilitating installation. The laminated spring's structure is optimized for easier demolding, preventing damage to the rubber during mold opening and ensuring product quality.

[0045] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of the present invention.

Claims

1. A method for manufacturing an integrated laminated spring, characterized in that: The rubber pad top plate and the stopper base are designed as an integrated structure, and the rubber pad mold and the stopper mold are designed as an integral mold; the rubber pad bottom plate, the rubber pad rubber iron piece, the rubber pad top plate and the stopper base integrated structure, the stopper rubber iron piece, and the stopper top plate are placed in the integral mold, and rubber is injected into the integral mold to make the rubber pad and the stopper become one; a rubber flow channel is provided that runs through the rubber pad cavity, the rubber pad top plate, the stopper base, and the stopper cavity; during vulcanization, rubber is injected into the rubber pad cavity, and the rubber enters the stopper cavity through the rubber flow channel from the rubber pad cavity to complete the integrated glue injection vulcanization; the number of rubber flow channels is at least 2, and the diameter of the rubber flow channel is more than 1 mm; the installation position of the mold insert on the top of the stopper is set to an arc shape that is convenient for product production and demolding.

2. The method for manufacturing an integrated laminated spring according to claim 1, wherein: The rubber material is natural rubber, chloroprene rubber or isoprene rubber.

3. The method for manufacturing an integrated laminated spring according to claim 1, wherein: Increase the thickness of the stop rubber profile to match the strength of the stop and rubber pad so that the stop rubber and rubber pad rubber use the same rubber compound.

4. The method for manufacturing an integrated laminated spring according to claim 3, wherein: The stop rubber profile is set to be linear and flush with the stop top plate. When demoulding, the mold of the stop part is demoulded upward.

5. The method for manufacturing an integrated laminated spring according to claim 1, wherein: The installation part of the mold insert at the top of the stopper is an arc shape inclined toward the outside.

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