Composite antenna beam device for rail vehicle and manufacturing method

Abstract

The application discloses a composite antenna beam device for a rail vehicle and a manufacturing method thereof. The device comprises a carbon fiber composite antenna beam body, a U-shaped clamping groove, a metal bushing and an anti-falling lifting lug. The middle part of the carbon fiber composite antenna beam body comprises a body crossbeam, an inner mounting ring and an outer mounting ring. The body crossbeam and the inner mounting ring are arranged along the radial direction and are covered by the outer mounting ring. The U-shaped clamping groove is a flat-bottom structure for wire clamp installation and is arranged along the axial direction of the carbon fiber composite antenna beam body. The metal bushing is embedded in the carbon fiber composite antenna beam body. The anti-falling lifting lug is fixed to the two ends of the carbon fiber composite antenna beam body. The method is used for manufacturing the device. The application has the advantages of simple structure, high lightweight degree, convenient processing and high structural strength.

Description

Technical Field

[0001] This invention mainly relates to the field of antenna beam technology for rail vehicles, specifically a composite material antenna beam device and manufacturing method for rail vehicles. Background Technology

[0002] With rapid economic development, lightweighting has become a new research direction in various industries, and it is of even greater significance for rail vehicles. Lightweighting of rail vehicles can save energy, promote sustainable development, reduce the load on load-bearing parts, and improve vehicle service life and safety.

[0003] Currently, the materials used for antenna beams of auxiliary devices for rail vehicle bogies are mostly carbon steel. Lightweighting is mostly achieved through structural optimization or the use of low-density alloys, which have limited lightweighting effects. Moreover, for antenna beam products with strict requirements on structural dimensions and mechanical properties, ordinary weight reduction solutions are greatly restricted in application.

[0004] Carbon fiber composites are advanced composite materials with carbon fiber as the reinforcement and resin as the matrix. They possess high specific strength, high specific modulus, low density, fatigue resistance, and excellent damping, vibration reduction, and noise reduction properties. Furthermore, carbon fiber composites exhibit good corrosion resistance, radiation resistance, and high and low temperature resistance, enabling their application in complex environments and expanding the application scope and service life of equipment.

[0005] Based on this, using carbon fiber composite materials to manufacture antenna beams for bogies of rail vehicles can greatly reduce the overall structural weight of the antenna beams, improve the operational stability of rail vehicles, and bring significant economic benefits to society. Summary of the Invention

[0006] The technical problem to be solved by this invention is: in view of the technical problems existing in the prior art, this invention provides a composite material antenna beam device for rail vehicles with simple structure, high lightweight, convenient processing and high structural strength, and a manufacturing method thereof.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A composite material antenna beam device for rail vehicles includes a carbon fiber composite antenna beam body, a U-shaped slot, metal bushings, and anti-detachment lugs. The middle part of the carbon fiber composite antenna beam body includes a main crossbeam, an inner mounting ring, and an outer mounting ring. The main crossbeam and the inner mounting ring are arranged radially and covered by the outer mounting ring. The U-shaped slot is a flat-bottomed structure for wire clamp installation and is arranged along the axial direction of the carbon fiber composite antenna beam body. The metal bushings are all pre-embedded in the carbon fiber composite antenna beam body, and the anti-detachment lugs are fixed to both ends of the carbon fiber composite antenna beam body.

[0008] As a further improvement to the above technical solution: the upper surfaces of both ends of the main crossbeam of the carbon fiber composite antenna beam are surface platforms for connecting the bogie.

[0009] As a further improvement to the above technical solution: the main crossbeam of the carbon fiber composite antenna beam is a "U" shaped structure with a circular arc transition design, the wall thickness remains unchanged, and the cross-sectional shape and cross-sectional area gradually decrease from both sides of the crossbeam to the middle.

[0010] As a further improvement to the above technical solution: both the inner mounting ring and the outer mounting ring are structures with equal cross-section and equal wall thickness.

[0011] As a further improvement to the above technical solution: the U-shaped slot is a flat-bottomed structure for wire clamp installation, and is uniformly glued and fixed along the axial direction of the carbon fiber composite antenna beam body with a limited period.

[0012] As a further improvement to the above technical solution: the U-shaped slot is located on the arc surface of the carbon fiber composite antenna beam body.

[0013] As a further improvement to the above technical solution: the U-shaped slot is connected to the arc surface of the carbon fiber composite antenna beam body by resin bonding; the wire clamp is connected to the slot opening of the U-shaped slot by bolts; the bottom of the U-shaped slot adopts a flat bottom structure.

[0014] As a further improvement to the above technical solution: all the metal bushings are designed as "I" shaped bushings.

[0015] As a further improvement to the above technical solution: the anti-detachment lugs are fitted with bolt holes with low stress at both ends of the carbon fiber composite antenna beam body and installed in the bolt connection between the carbon fiber composite antenna beam and the bogie.

[0016] This invention further provides a method for manufacturing a composite material antenna beam device for rail vehicles according to any one of the above claims, wherein the carbon fiber composite material antenna beam adopts a pressure bag molding process with an internal air bag and an external steel mold; it includes: Step S1: Cut the carbon fiber prepreg on a CNC machine tool; Step S2: When cutting, make holes at the corresponding positions of the metal bushing, roll the material on the mandrel, and pre-form the metal bushing into one piece during the rolling process. The layup sequence and angle of the rolled material are optimized and confirmed based on finite element simulation analysis. Step S3: After the material is rolled up, it is placed into a pre-processed external steel mold, cured and shaped in a forming furnace, and then the mold is removed.

[0017] As a further improvement to the above technical solution: a distributed molding process is adopted during the rolling process, and the main crossbeam, inner mounting ring and outer mounting ring of the carbon fiber composite antenna beam are rolled from different prepreg fabrics. The outer mounting ring is used to roll and assemble the inner mounting ring with the main crossbeam of the carbon fiber composite antenna beam.

[0018] As a further improvement to the above technical solution: the U-shaped slot is connected to the arc surface of the carbon fiber composite antenna beam body by resin bonding; the wire clamp is connected to the slot opening of the U-shaped slot by bolts; the bottom of the U-shaped slot adopts a flat bottom structure, and the gap between the arc surface of the beam and the flat bottom is filled with resin.

[0019] As a further improvement to the above technical solution: the anti-detachment lugs are matched with the two bolt holes with lower stress at the left and right ends of the carbon fiber composite antenna beam body according to the actual working conditions, and are installed in the bolt connection between the carbon fiber composite antenna beam and the bogie.

[0020] Compared with the prior art, the advantages of the present invention are as follows: 1. The composite material antenna beam device and manufacturing method for rail vehicles of the present invention have a simple structure, high lightweighting, and convenient processing. The main body of the antenna beam is made of carbon fiber composite material, which can reduce weight by more than 50% compared with a metal antenna beam of the same specifications, thus meeting the lightweighting requirements of key auxiliary components of rail train bogies. The use of carbon fiber resin-based reinforcement effectively avoids the resonance range of the bogie while ensuring the fatigue life of the antenna beam. The excellent damping characteristics of the carbon fiber composite material in the antenna beam body replace the traditional metal vibration damping mechanism, achieving vibration damping while improving the overall lightweighting effect and reducing the complexity of the overall structure.

[0021] 2. The composite material antenna beam device and manufacturing method for rail vehicles of the present invention have a U-shaped structure for the main crossbeam of the carbon fiber composite material antenna beam. The crossbeam adopts a circular arc transition design, and its wall thickness remains unchanged. The cross-sectional shape and cross-sectional area gradually decrease from both sides of the crossbeam to the middle, which solves the stress concentration problem of traditional metal antenna beams, improves the low-order mode frequency, and simplifies the manufacturing process.

[0022] 3. The composite material antenna beam device and manufacturing method for rail vehicles of the present invention employs a pressure bag molding process using an internal air bag and an external steel mold for the carbon fiber composite material antenna beam. The external mold uses a steel mold, and the internal air bag uses an air bag. The arc-shaped surface where the metal bushing contacts the carbon fiber prepreg is designed with grooves. The metal bushing and the main body of the carbon fiber composite antenna beam are integrally molded. The extrusion and ductility of the prepreg are used to fully fill the grooves with the carbon fiber composite material. After curing, bidirectional anti-delamination performance is achieved, while simultaneously achieving a completely flat surface both inside and out. Experimental verification shows that the composite structure and manufacturing method of the present invention can fully meet and guarantee the reliability of the connection.

[0023] 4. The composite material antenna beam device and manufacturing method for rail vehicles of the present invention adopts a step-by-step molding process for assembling the main crossbeam, inner mounting ring and outer mounting ring of the carbon fiber composite antenna beam. The main crossbeam and inner mounting ring of the carbon fiber composite antenna beam are respectively rolled from prepreg fabric. Then, the outer mounting ring is used to roll and cover the inner mounting ring and the main crossbeam of the carbon fiber composite antenna beam together, which satisfies the mechanical performance of the antenna beam while reducing the manufacturing cost. 5. The composite material antenna beam device and manufacturing method for rail vehicles of the present invention, wherein the anti-loosening lug is used to cooperate with two bolt holes with low stress at the left and right ends of the carbon fiber composite antenna beam in actual working conditions, and is installed in the bolt connection between the carbon fiber composite antenna beam and the bogie, providing vibration reduction function while preventing loosening of the bolt connection between the antenna beam and the bogie and ensuring the reliability of the connection.

[0024] 6. The composite material antenna beam device and manufacturing method for rail vehicles of the present invention uses a flat-bottomed U-shaped slot for wire clamp installation. The gap between the arc surface and the flat bottom of the beam is filled with resin by adhesive bonding. After testing, the adhesive bonding strength is reliable and sufficient to meet the working conditions. Attached Figure Description

[0025] Figure 1 This is a three-dimensional isometric view of the composite material antenna beam device for rail vehicles according to the present invention.

[0026] Figure 2 yes Figure 1 Cross-sectional view of the middle part of the main body of the carbon fiber composite antenna beam.

[0027] Figure 3 This is a three-dimensional isometric view of the metal bushing of the U-shaped slot in a specific application example of the present invention.

[0028] Figure 4 This is a schematic diagram of the structural principle of the first metal liner in a specific application example of the present invention.

[0029] Figure 5This is a schematic diagram of the structural principle of the second metal liner in a specific application example of the present invention.

[0030] Figure 6 This is a schematic diagram of the structural principle of the third metal liner in a specific application example of the present invention.

[0031] Figure 7 This is a three-dimensional isometric view of the anti-detachment lug in this invention.

[0032] Figure 8 This is a flowchart illustrating the manufacturing method of the present invention. Detailed Implementation

[0033] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0034] In the description of this application, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0035] In this application, unless otherwise expressly specified and limited, the terms "assembly," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0036] like Figures 1-5 As shown, the composite material antenna beam device for rail vehicles of the present invention includes a carbon fiber composite antenna beam body 1, a U-shaped slot 2, a metal bushing 3, and an anti-detachment lug 4; the middle part of the carbon fiber composite antenna beam body 1 includes a main crossbeam 101, an inner mounting ring 102, and an outer mounting ring 103, the main crossbeam 101 and the inner mounting ring 102 are arranged radially and covered by the outer mounting ring 103; the U-shaped slot 2 is a flat-bottomed structure for wire clamp installation and is arranged along the axial direction of the carbon fiber composite antenna beam body 1; the metal bushings 3 are all pre-embedded in the carbon fiber composite antenna beam body 1, and the anti-detachment lug 4 is fixed to both ends of the carbon fiber composite antenna beam body 1.

[0037] In a specific application example, the upper surfaces at both ends of the main crossbeam 101 of the carbon fiber composite antenna beam body 1 are surface platforms 1011 for connecting the bogie; the surface dimensions of the surface platform 1011 are extended (194mm) to the horizontal radial dimension of the antenna beam of 120mm according to the specific interference of the damper and bogie assembled with the antenna beam, and the axial dimension is determined to be 120mm to ensure the correct connection between the antenna beam and the bogie.

[0038] In a specific application example, the main crossbeam 101 of the carbon fiber composite antenna beam has a "U" shaped structure with a rounded transition design. Its wall thickness remains unchanged, and its cross-sectional shape and cross-sectional area gradually decrease from both sides of the crossbeam to the middle.

[0039] In specific application examples, both the inner mounting ring 102 and the outer mounting ring 103 are structures with equal cross-sections and equal wall thicknesses.

[0040] In specific application examples, the U-shaped slot 2 is a flat-bottomed structure for wire clamp installation (such as a U999 type slot), which is glued and fixed along the axial direction of the carbon fiber composite antenna beam body 1 with a limited period, and is generally located on the arc surface of the carbon fiber composite antenna beam body 1.

[0041] In specific application examples, the metal bushings 3 are all designed as "I"-shaped bushings. The variation in the outer diameter of the upper and lower circles of the "I"-shaped metal bushing 3 can reduce stress concentration at the connection. For a certain surface where stress concentration occurs, a larger outer diameter is selected. Grooves are designed on the arc surface in contact with the carbon fiber. Utilizing the extrusion and ductility of the carbon fiber prepreg during integral molding, the carbon fiber composite material is fully filled into the groove, achieving bidirectional anti-delamination performance after curing. Considering the thermal expansion and contraction factors of the molding die, the metal bushing 3 is integrally molded and then the inner hole is machined as a whole, making the precision more controllable. Three different metal bushings are provided for different connection positions between the carbon fiber composite antenna beam body 1 and the bogie, suitable for different connection positions. See also... Figure 4 , Figure 5 and Figure 6 The three different metal bushings 3 are the first metal liner 301, the second metal liner 302, and the third metal liner 303.

[0042] In specific application examples, according to actual needs, the material of the carbon fiber composite antenna beam body 1 in this invention is carbon fiber composite material. The resin and fiber type and carbon fiber layup sequence are confirmed according to the simulation analysis results. The U-shaped slot 2, the first metal liner 301 and the anti-detachment lug 4 are made of carbon steel. The second metal liner 302 and the third metal liner 303 are made of high-strength alloy materials such as Q550D, considering the stress concentration at the connection with the bogie.

[0043] In a specific application example, the U-shaped slot 2 is connected to the arc surface of the carbon fiber composite antenna beam body 1 by resin bonding; the wire clamp is connected to the slot opening of the U-shaped slot 2 by bolts; the bottom of the U-shaped slot 2 adopts a flat bottom structure, and the gap between the arc surface of the beam and the flat bottom is filled with resin.

[0044] In a specific application example, the anti-detachment lug 4 is fitted with two bolt holes with lower stress at the left and right ends of the carbon fiber composite antenna beam body 1 according to the actual working conditions, and is installed in the bolt connection between the carbon fiber composite antenna beam and the bogie, with a thickness of 5mm.

[0045] like Figure 8 As shown, the present invention further provides a method for manufacturing the above-mentioned composite material antenna beam device for rail vehicles, wherein the carbon fiber composite antenna beam body 1 adopts a pressure bag molding process with an internal air bag and an external steel mold; it includes: Step S1: Cut the carbon fiber prepreg on a CNC machine tool; Step S2: When cutting, make holes at the corresponding positions of the metal bushing 3, roll the material on the air bag, and pre-form the metal bushing 3 into one piece during the rolling process. The laying sequence and angle of the rolled material are optimized and confirmed based on finite element simulation analysis. Step S3: After the material is rolled up, it is placed into a pre-processed external steel mold, cured and shaped in a forming furnace, and then the mold is removed.

[0046] See Figure 2 Furthermore, in specific application examples, a distributed molding process is adopted during the rolling process. The carbon fiber composite antenna beam main crossbeam 101, inner mounting ring 102 and outer mounting ring 103 are rolled from different prepreg fabrics. The outer mounting ring 103 is used to roll and assemble the inner mounting ring 102 and the carbon fiber composite antenna beam main crossbeam 101 together.

[0047] Furthermore, in a specific application example, the U-shaped slot 2 is connected to the arc surface of the carbon fiber composite antenna beam body 1 by resin bonding; the wire clamp is connected to the slot opening of the U-shaped slot 2 by bolts; the bottom of the U-shaped slot 2 adopts a flat bottom structure, and the gap between the arc surface of the beam and the flat bottom is filled with resin.

[0048] Furthermore, in a specific application example, the anti-detachment lug 4 is fitted with two bolt holes with lower stress at the left and right ends of the carbon fiber composite antenna beam body 1 according to the actual working conditions, and is installed in the bolt connection between the carbon fiber composite antenna beam and the bogie.

[0049] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A composite material antenna beam device for rail vehicles, characterized in that, The antenna beam body includes a carbon fiber composite antenna beam body (1), a U-shaped slot (2), a metal bushing (3), and an anti-detachment lug (4). The middle part of the carbon fiber composite antenna beam body (1) includes a main crossbeam (101), an inner mounting ring (102), and an outer mounting ring (103). The main crossbeam (101) and the inner mounting ring (102) are arranged radially and covered by the outer mounting ring (103). The U-shaped slot (2) is a flat-bottomed structure for wire clamp installation and is arranged along the axial direction of the carbon fiber composite antenna beam body (1). The metal bushing (3) is embedded in the carbon fiber composite antenna beam body (1), and the anti-detachment lug (4) is fixed at both ends of the carbon fiber composite antenna beam body (1).

2. The composite material antenna beam device for rail vehicles according to claim 1, characterized in that, The upper surfaces at both ends of the main crossbeam (101) of the carbon fiber composite antenna beam body (1) are surface platforms (1011) for connecting the bogie.

3. The composite material antenna beam device for rail vehicles according to claim 1, characterized in that, The main crossbeam (101) of the carbon fiber composite antenna beam has a "U" shaped structure with a circular arc transition design. The wall thickness remains unchanged, and the cross-sectional shape and cross-sectional area gradually decrease from both sides of the crossbeam to the middle.

4. The composite material antenna beam device for rail vehicles according to claim 1, characterized in that, Both the inner mounting ring (102) and the outer mounting ring (103) are structures with equal cross-sections and equal wall thicknesses.

5. The composite material antenna beam device for rail vehicles according to any one of claims 1-4, characterized in that, The U-shaped slot (2) is a flat-bottomed structure for wire clamp installation, and is uniformly glued and fixed along the axial direction of the carbon fiber composite antenna beam body (1) with a limited period.

6. The composite material antenna beam device for rail vehicles according to claim 5, characterized in that, The U-shaped slot (2) is located on the arc surface of the carbon fiber composite antenna beam body (1).

7. The composite material antenna beam device for rail vehicles according to any one of claims 1-4, characterized in that, The U-shaped slot (2) is connected to the arc surface of the carbon fiber composite antenna beam body (1) by resin bonding; the wire clamp is connected to the slot opening of the U-shaped slot (2) by bolts; the bottom of the U-shaped slot (2) adopts a flat bottom structure.

8. The composite material antenna beam device for rail vehicles according to any one of claims 1-4, characterized in that, All metal bushings (3) are designed as "I" shaped bushings.

9. The composite material antenna beam device for rail vehicles according to any one of claims 1-4, characterized in that, The anti-detachment lug (4) is fitted with the bolt holes at both ends of the carbon fiber composite antenna beam body (1) and installed in the bolt connection between the carbon fiber composite antenna beam body (1) and the bogie.

10. A method for manufacturing a composite material antenna beam device for rail vehicles according to any one of claims 1-9, characterized in that, The carbon fiber composite antenna beam body (1) adopts a pressure bag molding process with an internal air bag and an external steel mold; It includes: Step S1: Cut the carbon fiber prepreg on a CNC machine tool; Step S2: When cutting, make holes at the corresponding positions of the metal bushing (3), roll the material on the core mold, and preform the metal bushing (3) into one piece during the rolling process. The roll layer sequence and angle are optimized and confirmed based on finite element simulation analysis. Step S3: After the material is rolled up, it is placed into a pre-processed external steel mold, cured and shaped in a forming furnace, and then the mold is removed.

11. The manufacturing method according to claim 10, characterized in that, The roll forming process is adopted. The main crossbeam (101), inner mounting ring (102) and outer mounting ring (103) of the carbon fiber composite antenna beam are made of different prepreg fabrics. The outer mounting ring (103) is used to roll and assemble the inner mounting ring (102) and the main crossbeam (101) of the carbon fiber composite antenna beam together.

12. The manufacturing method according to claim 10, characterized in that, The U-shaped slot (2) is connected to the arc surface of the carbon fiber composite antenna beam body (1) by resin bonding; the wire clamp is connected to the slot opening of the U-shaped slot (2) by bolts; the bottom of the U-shaped slot (2) adopts a flat bottom structure, and the gap between the arc surface of the beam and the flat bottom is filled with resin.

13. The manufacturing method according to claim 10, characterized in that, The anti-detachment lug (4) is installed in the bolt connection between the carbon fiber composite antenna beam and the bogie, according to the actual working conditions and the two bolt holes at the left and right ends of the carbon fiber composite antenna beam body (1).

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