Methods for controlling the coupler height of railway vehicles

Abstract

This invention discloses a method for controlling the coupler height of railway vehicles, comprising the following steps: 1) During underframe assembly, the lower flanges of the end beam and the middle beam are fitted together, ensuring the gap between them is less than 1mm; 2) The upper surface of the coupler support is controlled to be horizontal, and the upper surface of the stop block is tightly fitted with the lower surface of the impact seat's abutment; the vertical distance between the upper surface of the coupler support and the lower surface of the upper center plate is controlled to be 95-99mm, ensuring the traction beam is horizontal or drooping, with the drooping distance of the traction beam less than or equal to 4mm; 3) The vertical distance between the upper surface of the coupler support and the lower surface of the middle beam wear plate is accurately measured and controlled; wherein, during measurement, the lower surface of the middle beam wear plate is used as a reference, and the vertical distance between the middle of the upper surface of the coupler support and the lower surface of the middle beam wear plate is measured. This control method can improve the qualification rate of coupler height.

Description

Technical Field

[0001] This invention relates to a method for controlling the coupler height of railway vehicles. Background Technology

[0002] Couplers are one of the important components of railway vehicles. Railway vehicles are connected by couplers, which serve both connecting and traction functions. The coupler height of a railway vehicle refers to the vertical distance between the horizontal centerline of the coupler and the upper surface of the horizontal rail.

[0003] During train operation, if the height difference between two connected couplers exceeds the allowable range, it will affect the reliability and stability of the train, and may even endanger the safe operation of the train. Railway vehicle manufacturing standards have strict requirements for the coupler height and related parameters of railway vehicles. Therefore, the coupler height must be strictly controlled during vehicle manufacturing to meet the requirements of coupler height dimensions and manufacturing technology conditions, so as to achieve the goal of safe vehicle operation.

[0004] Currently, the main methods for adjusting the coupler height include: adjusting the coupler height by replacing the wear plates of coupler support seats of different thicknesses when the vehicle is completed to meet the relevant requirements. This method has the following problems: (1) It involves a lot of human factors and is only effective for models that have already been produced, lacking effective guidance for new models; (2) If any part of the process changes, a large amount of work-in-progress will be generated by the time it is discovered, resulting in a waste of manpower and resources, and failing to play a preventive and control role.

[0005] Currently, in the actual production of railway vehicles, due to the many factors affecting the coupler height and the complexity of the related dimensions, intermittent coupler height deviations and rework issues may occur due to individual problems. Summary of the Invention

[0006] In view of this, the purpose of this invention is to provide a method for controlling the coupler height of railway vehicles. The control method of this invention can significantly improve the pass rate of coupler height. This objective is achieved through the following technical solution.

[0007] This invention provides a method for controlling the coupler height of railway vehicles, comprising the following steps:

[0008] 1) When assembling the base frame, fit the lower flange of the end beam and the middle beam together, and make the gap between the lower flange of the end beam and the middle beam less than 1mm.

[0009] 2) Control the upper surface of the coupler support to be horizontal, and make the upper surface of the stop iron close to the lower surface of the impact seat; control the vertical distance between the upper surface of the coupler support and the lower surface of the upper center plate to be 95-99mm, and make the traction beam horizontal or drooping, and the drooping distance of the traction beam is less than or equal to 4mm.

[0010] 3) accurately measure and control the vertical distance between the upper surface of the coupler support seat and the lower surface of the middle beam wear plate; wherein, in the measurement, the lower surface of the middle beam wear plate is taken as the reference, and the vertical distance between the middle part of the upper surface of the coupler support seat and the lower surface of the middle beam wear plate is measured.

[0011] The railway vehicle manufacturing standard requires that the coupler height of the railway vehicle is 870-890mm, and the height difference of the horizontal center line of the two couplers of the same vehicle is less than or equal to 10mm. When the height difference of the two couplers connected to each other exceeds the allowable range during vehicle operation, the reliability and stability of the train will be affected, and even the operation safety of the vehicle will be endangered. Therefore, the coupler height of the railway vehicle is strictly controlled by a certain control method during the manufacture of the railway vehicle. In this way, it can ensure that the railway vehicle has a high inspection qualified rate when it is delivered, ensure the safe operation of the railway vehicle, and greatly reduce the repair.

[0012] Through research and experiment, it is found that in the chassis assembly process, the gap between the end beam and the lower wing surface of the middle beam is less than or equal to 1mm, which is beneficial to control the coupler height range. The assembly of the end beam is the basis for the assembly of the impact seat, the stop iron and the coupler support seat. The position of the end beam assembly must be appropriate to ensure the correct position and size of other parts after assembly.

[0013] In the present application, the middle beam is deflected upward between the two bolster beams, and the deflection distance of the middle beam is less than or equal to 4mm; the deflection distance of the side beam is less than or equal to 4mm; the height difference between the middle beam, the bolster beam and the side beam on the same cross section is less than or equal to 5mm. The chassis is corrected again. In this way, it is beneficial to ensure that the position of the coupler support seat is appropriate and the deflection distance of the traction beam is within a suitable range, thereby facilitating the control of the coupler height within the ideal range.

[0014] The chassis assembly process described in the present application can also include adjusting the assembly position and gap of each transverse beam and longitudinal beam, and the assembly should be perpendicular to each other. The contents not described in the present application, such as chassis assembly and chassis correction, can refer to the railway vehicle manufacturing standard, and will not be described here.

[0015] Generally, the riveting operation of the stop iron is in the assembly procedure of the coupler buffer device. Through research and experiment, it is found that adjusting the riveting operation of the stop iron (or the coupler support seat) to the chassis assembly process is beneficial to control the vertical distance between the upper surface of the coupler support seat and the lower surface of the upper center plate, thereby facilitating the control of the coupler height within a suitable range.

[0016] According to one embodiment of the present application, the car coupler support seat and the stop iron are connected; before the stop iron is riveted to the impact seat, the spring is checked to avoid the spring from being out of the inner cavity casting protrusion of the impact seat; then the stop iron is riveted to the impact seat by the pull rivet, and the upper surface of the stop iron is leveled, the upper surface of the car coupler support seat is leveled, and the upper surface of the stop iron is tightly attached to the lower surface of the bearing platform part of the impact seat.

[0017] According to another embodiment of the present application, the vertical distance between the upper surface of the car coupler support seat and the lower surface of the upper center plate is controlled to be 95-99 mm, and the drawbar is leveled or sagged, and the sagging distance of the drawbar is less than or equal to 4 mm. This is beneficial to ensure that the height of the car coupler is in a more ideal range.

[0018] The same vehicle has two car couplers, which are respectively referred to as a one-car coupler and a two-car coupler. The car coupler support seats are respectively arranged at the two-car coupler positions. The vertical distance between the upper surface of the car coupler support seat at the one-car coupler end and the lower surface of the upper center plate and the vertical distance between the upper surface of the car coupler support seat at the two-car coupler end and the lower surface of the upper center plate can be the same or different. The sagging distance of the drawbar at the one-car coupler end and the sagging distance of the drawbar at the two-car coupler end can be the same or different.

[0019] In the present application, the flatness of the lower surface of the bearing platform part of the impact seat is controlled to be less than or equal to 1 mm. This is beneficial to prevent the existence of casting defects on the surface from affecting the assembly position of the stop iron and causing changes in the height of the car coupler.

[0020] In the present application, the vertical distance between the center of the bottom hole of the impact seat and the lower surface of the bearing platform part of the impact seat is controlled to be 96±1 mm. More preferably, the vertical distance between the center of the bottom hole of the impact seat and the lower surface of the bearing platform part of the impact seat is controlled to be 96±0.5 mm. The distance between the center of the bottom hole of the impact seat and the lower surface of the bearing platform part is measured with an accuracy of less than or equal to 0.1 mm. This is beneficial to control the height of the car coupler within a standard range.

[0021] In the present application, the height of the car coupler support seat is controlled to be 95-97 mm. It is found in the present application that the car coupler support seat is a casting, and controlling the height of the car coupler support seat within the above range is beneficial to prevent the car coupler height from changing due to a large deviation in the height dimension of the car coupler support seat.

[0022] It is also found through research and experiments that controlling the relevant dimensions of the hook tail is conducive to controlling the height of the coupler within an ideal range. In the present application, the vertical distance between the upper surface of the coupler support seat and the lower surface of the middle beam wear plate is accurately measured and controlled. When measuring, the lower surface of the middle beam wear plate is used as the reference to measure the vertical distance between the middle part of the upper surface of the coupler support seat and the lower surface of the middle beam wear plate. The vertical distance between the upper surface of the coupler support seat and the lower surface of the middle beam wear plate is controlled to be 243±0.1mm. The center offset between the support plate and the fixed end hook tail frame wear plate is controlled to be less than 1mm.

[0023] In actual production, since the coupler support seat and the impact seat are both castings, three springs with supporting functions are compressed in the middle during assembly, and it is difficult for the upper surface of the coupler support seat to be completely horizontal after assembly. Due to the inclination problem of the upper surface of the coupler support seat after assembly, and due to the fact that the distance between the upper surface of the coupler support seat and the lower surface of the middle beam wear plate is a spatial distance, it is difficult to measure and the measurement result is not accurate. It is found through research that, by using the lower surface of the middle beam wear plate as the reference, directly measuring the distance between the middle part of the upper surface of the coupler support seat and the lower surface of the middle beam wear plate is conducive to improving the accuracy and precision of the measured size.

[0024] In the present application, the assembly position of the hook tail frame wear plate is controlled, i.e., the center offset between the support plate and the fixed end hook tail frame wear plate is controlled to be less than 1mm, which is conducive to reducing the influence on the height of the coupler.

[0025] According to the control method of the present application, preferably, the flatness of the lower surface of the bearing part of the impact seat is controlled to be less than 1mm. More preferably, the flatness of the lower surface of the bearing part of the impact seat is controlled to be less than or equal to 0.6mm.

[0026] According to the control method of the present application, preferably, the measurement accuracy of the distance between the center of the bottom hole of the impact seat and the lower surface of the bearing part of the impact seat is controlled to be less than 0.1mm.

[0027] According to the control method of the present application, preferably, the height of the coupler support seat is controlled to be 95-97mm. In some embodiments, the height of the coupler support seat is controlled to be 95mm. In other embodiments, the height of the coupler support seat is controlled to be 96mm. In still other embodiments, the height of the coupler support seat is controlled to be 97mm.

[0028] The height of the coupler support seat at one end of the coupler and the height of the coupler support seat at the other end of the coupler can be the same or different.

[0029] According to the control method of the present application, preferably, the vertical distance between the middle part of the upper surface of the coupler support seat and the lower surface of the middle beam wear plate is controlled to be 243±0.1mm.

[0030] According to the control method, preferably, the center offset between the support plate and the fixed end knuckle tail frame wear plate is less than or equal to 1 mm. More preferably, the center offset between the support plate and the fixed end knuckle tail frame wear plate is less than or equal to 0.7 mm.

[0031] According to the control method, preferably, the thickness of the knuckle adjusting pad plate is 8-14 mm. The thickness of the knuckle adjusting pad plate can be 8 mm, 10 mm, 12 mm or 14 mm.

[0032] The thickness of the knuckle adjusting pad plate at the one end of the car coupler and the thickness of the knuckle adjusting pad plate at the other end of the car coupler can be the same or different.

[0033] In some embodiments, the thickness of the knuckle adjusting pad plate at the one end of the car coupler is 12 mm, and the thickness of the knuckle adjusting pad plate at the other end of the car coupler is 10 mm. In other embodiments, the thickness of the knuckle adjusting pad plate at the one end of the car coupler is 10 mm, and the thickness of the knuckle adjusting pad plate at the other end of the car coupler is 10 mm. In still other embodiments, the thickness of the knuckle adjusting pad plate at the one end of the car coupler is 10 mm, and the thickness of the knuckle adjusting pad plate at the other end of the car coupler is 14 mm. In yet other embodiments, the thickness of the knuckle adjusting pad plate at the one end of the car coupler is 8 mm, and the thickness of the knuckle adjusting pad plate at the other end of the car coupler is 10 mm.

[0034] According to the control method, preferably, the following specific steps are included:

[0035] 1) When assembling the underframe, the end beam is clamped and the lower wing surface of the end beam is attached to the lower wing surface of the center beam, so that the gap between the end beam and the lower wing surface of the center beam is less than or equal to 1 mm;

[0036] 2) The car coupler support seat and the stop iron are connected, and the stop iron is riveted to the impact seat; wherein the upper surface of the car coupler support seat is controlled to be horizontal, and the upper surface of the stop iron is tightly attached to the lower surface of the bearing part of the impact seat; the vertical distance between the upper surface of the car coupler support seat and the lower surface of the upper center disc is controlled to be 95-99 mm, and the traction beam is in a horizontal or drooping state, and the drooping distance of the traction beam is less than or equal to 4 mm;

[0037] 3) The vertical distance between the upper surface of the car coupler support seat and the lower surface of the center beam wear plate is accurately measured and controlled; wherein when measuring, the lower surface of the center beam wear plate is taken as the reference to measure the vertical distance between the middle part of the upper surface of the car coupler support seat and the lower surface of the center beam wear plate.

[0038] According to the control method, preferably, the spring is checked before riveting to avoid the spring from being cast out of the inner cavity of the impact seat; then the stop iron of the car coupler support seat is riveted to the impact seat by pull rivets, and the upper surface of the stop iron is made horizontal.

[0039] According to the control method, preferably, the vertical distance between the center of the top hole of the impact seat and the upper surface of the end beam is 162 mm; the middle beam is deflected upward between the two bolster beams, and the upward or downward deflection distance of the middle beam is less than or equal to 4 mm; the upward or downward deflection distance of the side beam is less than or equal to 4 mm; and the height difference between the middle beam, the bolster beam and the side beam on the same cross section is less than or equal to 5 mm.

[0040] The control method can improve the first-time inspection qualified rate of the coupler height, ensure the safe operation of the railway vehicle, and greatly reduce the rework. According to the preferred technical solution of the present application, the control method can eliminate the adverse conditions and factors of the coupler height in advance by adjusting and controlling the coupler height range in the chassis assembly process and the chassis correction process, which is beneficial to ensure the qualified rate of the coupler height and reduce the rework. The control method can make the first-time inspection qualified rate of the coupler height reach 98.72%, which is significantly higher than the traditional first-time inspection qualified rate of 90%. BRIEF DESCRIPTION OF DRAWINGS

[0041] Figure 1 is a schematic view of the impact seat of the present application.

[0042] Figure 2 is a schematic view of the coupler support seat of the present application.

[0043] BRIEF DESCRIPTION OF DRAWINGS

[0044] 10-coupler support seat, h1-height of the coupler support seat, 20-impact seat, 21-top hole of the impact seat, 22-bottom hole of the impact seat, A-lower surface of the bearing part of the impact seat, h2-vertical distance between the center of the bottom hole of the impact seat and the lower surface of the bearing part of the impact seat. DETAILED DESCRIPTION

[0045] The present application will be further described below in conjunction with specific embodiments, but the scope of protection of the present application is not limited thereto.

[0046] Example 1

[0047] The control method of the coupler height of the railway vehicle of the present embodiment includes the following steps:

[0048] In the chassis assembly process, the lower part of the end beam is clamped, and the lower wing surface of the end beam and the middle beam is fitted, so that the gap between the lower wing surface of the end beam and the middle beam is equal to 1 mm. The middle beam is deflected upward between the two bolster beams, and the upward or downward deflection distance of the middle beam is less than or equal to 4 mm. The upward or downward deflection distance of the side beam is less than or equal to 4 mm; and the height difference between the middle beam, the bolster beam and the side beam on the same cross section is less than or equal to 5 mm.

[0049] Figure 1This is a schematic diagram of the impact seat of the present invention. Figure 1 As shown, the flatness of the lower surface A of the impact seat's base portion is less than 1 mm. The accuracy of the distance measurement between the center of the bottom hole 22 of the impact seat and the lower surface A of the impact seat's base portion is less than 0.1 mm. The vertical distance h2 between the center of the bottom hole 22 of the impact seat and the lower surface A of the impact seat's base portion is 96 ± 0.5 mm. The distance between the center of the top hole 21 of the impact seat and the upper surface of the end beam is 162 mm.

[0050] This ensures that the end beam is properly assembled and that the impact seat 20 is properly assembled, which is beneficial for controlling the coupler height.

[0051] The riveting operation of the stop block is adjusted to be in the underframe assembly process. This makes it easier to control the distance between the coupler support seat 10 and the upper center plate, thus ensuring that the coupler height is within a more ideal range. First, connect the coupler support seat 10 and the stop block. Then, rivet the stop block to the impact seat 20. Before riveting, check the spring to prevent it from popping out of the casting protrusion inside the impact seat 20. Then, rivet the stop block to the impact seat 20 with rivets, making the upper surface of the stop block horizontal. At the same time, control the upper surface of the coupler support seat 10 to be horizontal, and make the upper surface of the stop block tightly against the lower surface A of the impact seat's bearing platform. Figure 2 This is a schematic diagram of the coupler support base of the present invention. Figure 2 As shown, the height h1 of the coupler support is controlled to be 96±1mm. The vertical distance between the upper surface of the coupler support 10 and the lower surface of the upper center plate is controlled to be 95-99mm, so that the traction beam is horizontal or drooping, and the drooping distance of the traction beam is less than or equal to 4mm.

[0052] Accurately measure and control the vertical distance between the upper surface of the coupler support 10 and the lower surface of the center beam wear plate. During measurement, using the lower surface of the center beam wear plate as a reference, measure the vertical distance between the center of the upper surface of the coupler support 10 and the lower surface of the center beam wear plate. Control the vertical distance between the upper surface of the coupler support 10 and the lower surface of the center beam wear plate to be 243 ± 0.1 mm. Control the offset between the support plate and the center of the wear plate of the fixed end coupler frame to be less than 1 mm.

[0053] The same vehicle has two couplers, referred to as the first coupler and the second coupler. In this embodiment, the thickness of the coupler adjustment shim at the first coupler end is 12mm, and the thickness of the coupler adjustment shim at the second coupler end is 10mm.

[0054] The above control methods help ensure that the coupler height is 870–890 mm, and the height difference between the horizontal center lines of the two couplers on the same car is less than or equal to 10 mm. This helps ensure the reliability, stability, and safety of railway vehicle operation. Specific parameters are shown in Table 1.

[0055] Example 2

[0056] The difference from Embodiment 1 is that the vertical distance between the upper surface of the coupler support seat 10 and the lower surface of the upper center plate is different; the downward distance of the traction beam is also different. Specific parameters are shown in Table 1.

[0057] Example 3

[0058] The difference from Embodiment 1 is that the vertical distance between the upper surface of the coupler support seat 10 and the lower surface of the upper center plate is different; the downward distance of the traction beam is different; and the thickness of the coupler adjustment shim is different. Specific parameters are shown in Table 1.

[0059] Comparative Example 1

[0060] The difference from Embodiment 1 is that the vertical distance between the upper surface of the coupler support 10 and the lower surface of the upper center plate is different; the downward distance of the traction beam is different; and the coupler height is different. See Table 1 for specific parameters.

[0061] Table 1

[0062]

[0063] In summary, the control method of the present invention can control the coupler height within an ideal range, thereby improving the first-pass yield rate of the coupler height.

[0064] This invention is not limited to the above-described embodiments. Any modifications, improvements, or substitutions that can be conceived by those skilled in the art without departing from the essential content of this invention fall within the scope of this invention.

Claims

1. A method of controlling the height of a railway vehicle coupler, characterized by, The method comprises the following steps: 1) when assembling the underframe, the end beam is attached to the lower surface of the middle beam, and the gap between the end beam and the lower surface of the middle beam is less than 1 mm; 2) the upper surface of the car coupler support is controlled to be horizontal, and the upper surface of the stop iron is tightly attached to the lower surface of the bearing part of the impact seat; the vertical distance between the upper surface of the car coupler support and the lower surface of the upper center plate is controlled to be 95-99 mm, and the traction beam is horizontal or droops, and the drooping distance of the traction beam is less than or equal to 4 mm; 3) the vertical distance between the upper surface of the car coupler support and the lower surface of the middle beam wear plate is accurately measured and controlled; when measuring, the vertical distance between the middle part of the upper surface of the car coupler support and the lower surface of the middle beam wear plate is measured with the lower surface of the middle beam wear plate as a reference.

2. The control method according to claim 1, characterized by, The flatness of the lower surface of the bearing part of the impact seat is controlled to be less than 1 mm.

3. The control method according to claim 2, characterized by, The measurement accuracy of the distance between the center of the bottom hole of the impact seat and the lower surface of the bearing part of the impact seat is controlled to be less than 0.1 mm.

4. The control method according to claim 1, characterized by, The height of the car coupler support is controlled to be 95-97 mm.

5. The control method according to claim 1, characterized by, The vertical distance between the upper surface of the car coupler support and the lower surface of the middle beam wear plate is controlled to be 243±0.1 mm.

6. The control method according to claim 1, characterized by, The center offset of the support plate and the fixed end coupler tail frame wear plate is controlled to be less than 1 mm.

7. The control method according to any one of claims 1 to 6, characterized by, The thickness of the car coupler adjusting pad is 8-14 mm.

8. The control method according to claim 1, characterized by, The method comprises the following specific steps: 1) when assembling the underframe, the lower part of the end beam is tightly pressed, and the end beam is attached to the lower surface of the middle beam, so that the gap between the end beam and the lower surface of the middle beam is less than 1 mm; 2) the car coupler support and the stop iron are connected, and the stop iron is riveted to the impact seat; the upper surface of the car coupler support is controlled to be horizontal, and the upper surface of the stop iron is tightly attached to the lower surface of the bearing part of the impact seat; the vertical distance between the upper surface of the car coupler support and the lower surface of the upper center plate is controlled to be 95-99 mm, and the traction beam is horizontal or droops, and the drooping distance of the traction beam is less than or equal to 4 mm; 3) the vertical distance between the upper surface of the car coupler support and the lower surface of the middle beam wear plate is accurately measured and controlled; when measuring, the vertical distance between the middle part of the upper surface of the car coupler support and the lower surface of the middle beam wear plate is measured with the lower surface of the middle beam wear plate as a reference.

9. The control method according to claim 8, characterized by, Before riveting, the spring is checked to avoid the spring from escaping the inner cavity casting protrusion of the impact seat; then the stop iron of the car coupler support is riveted to the impact seat by pull rivets, and the upper surface of the stop iron is horizontal.

10. The control method according to claim 8, characterized by, The vertical distance between the center of the top hole of the impact seat and the upper surface of the end beam is 162 mm; the middle beam is upwarping between the two bolster beams, and the upwarping or drooping distance of the middle beam is less than or equal to 4 mm; the upwarping or drooping distance of the side beam is less than or equal to 4 mm; on the same cross section, the height difference between the middle beam, the bolster beam and the side beam is less than or equal to 5 mm.

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