A method for manufacturing a cellular aluminum end wall, a cellular aluminum end wall and a rail vehicle

Abstract

The application belongs to the field of manufacturing end walls of a rail vehicle body, and particularly relates to a honeycomb aluminum end wall manufacturing method, a honeycomb aluminum end wall and a rail vehicle. The application reduces post-welding deformation of the end wall through means such as assembly sequence optimization, welding parameter adjustment, welding sequence optimization, etc., guarantees the overall manufacturing precision of the honeycomb aluminum structure end wall after assembly welding through means such as assembly quantity setting and reverse deformation control, and realizes free adjustment and repair.

Description

Technical Field

[0001] This invention belongs to the field of manufacturing end walls for rail vehicles, specifically relating to a method for manufacturing honeycomb aluminum end walls, honeycomb aluminum end walls, and rail vehicles. Background Technology

[0002] With the increasing demand for lightweight rail vehicles, replacing the original plate-beam and profile end wall panels with honeycomb aluminum wall panels is one of the effective means to reduce vehicle weight. Honeycomb aluminum end walls effectively reduce end wall weight while maintaining structural strength.

[0003] However, the reduced thickness of the honeycomb aluminum wall panel joints places higher demands on welding quality. Furthermore, the thinner honeycomb aluminum structure skin makes the wall panel more susceptible to surface damage during manufacturing due to excessive pressure from tooling clamping. This increases the difficulty of clamping and prefabrication during welding. Moreover, common post-weld repair methods such as flame finishing and pressure finishing can easily cause irreversible structural or surface damage to the honeycomb aluminum wall panel. Therefore, strict control of the manufacturing precision of the honeycomb aluminum end walls is necessary to achieve repair-free operation. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the first objective of this invention is to provide a method for manufacturing a honeycomb aluminum end wall; the second objective is to provide a honeycomb aluminum end wall obtained by this method; and the third objective is to provide a rail vehicle including the honeycomb aluminum end wall.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0006] In a first aspect, embodiments of the present invention provide a method for manufacturing a honeycomb aluminum end wall, wherein the honeycomb aluminum end wall includes a first curved beam, a second curved beam, a third curved beam, a first honeycomb aluminum wall panel, a second honeycomb aluminum wall panel, a third honeycomb aluminum wall panel, a first column, a second column, a first crossbeam, a second crossbeam, and a third crossbeam, and the manufacturing steps are as follows:

[0007] The first, second, and third curved beams are placed face up on the welding fixture for assembly and welding.

[0008] Place the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel, the first column, and the second column face up onto the welding fixture in sequence. Then place the third honeycomb aluminum wall panel and the first crossbeam face up onto the welding fixture in sequence. Finally, place the second crossbeam and the third crossbeam face up onto the welding fixture in sequence.

[0009] Adjust the dimensions of the end wall outline, using the center line as the reference in the width direction and the bottom of the end wall as the reference in the height direction, and then press all the curved beams, wall panels, columns, and beams together in sequence.

[0010] Spot weld the weld seam on the front of the end wall and install process bracing to control the doorway size;

[0011] Welding of the front side of the end wall;

[0012] After the front weld has cooled, flip the end wall to the reverse assembly fixture with the reverse side of the workpiece facing up, and press the fixture together; then perform reverse welding.

[0013] This invention reduces post-weld deformation of the end wall by optimizing assembly and welding sequences. By setting assembly volume and controlling anti-deformation, it ensures the overall manufacturing precision of the honeycomb aluminum structure end wall assembly after welding, achieving maintenance-free operation.

[0014] As a further technical solution, when assembling from the front, assembly allowances should be set in both the width and length directions.

[0015] As a further technical solution, during front welding, the first honeycomb aluminum wall panel and the first and second columns are welded first, then the third honeycomb aluminum wall panel and the first column, the second column, and the first crossbeam are welded, then the first honeycomb aluminum wall panel and the second honeycomb aluminum wall panel and the first curved beam, the second curved beam, and the third curved beam are welded; finally, the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel, the second crossbeam, and the third crossbeam are welded.

[0016] As a further technical solution, the welding direction of the first, honeycomb aluminum wall panel and the first and second columns is from top to bottom, and the welding is carried out in three sections. Each section is welded after the weld of the previous section has cooled to room temperature; and the welding is carried out simultaneously on both sides.

[0017] As a further technical solution, the welding of the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel, the first curved beam, the second curved beam, and the third curved beam is carried out from the top center to the bottom of both sides, with simultaneous welding on both sides.

[0018] As a further technical solution, the welding of the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel, the second crossbeam, and the third crossbeam is performed from the center outwards to both sides.

[0019] As a further technical solution, clamping devices are fixed on the first curved beam, the second curved beam, the third curved beam, the first column, the second column, and the first crossbeam.

[0020] As a further technical solution, multiple clamping devices are provided, spaced a certain distance apart.

[0021] As a further technical solution, a clamping device with added nylon pads is installed on the first and second honeycomb aluminum wall panels.

[0022] As a further technical solution, the four corners of the contact surface between the nylon pad and the honeycomb aluminum wall panel should be rounded.

[0023] As a further technical solution, before reverse welding, pad blocks are used to raise the main deformation positions of the first and second honeycomb aluminum wall panels and press them together on both sides to make the reverse side of the wall panels convex.

[0024] As a further technical solution, the overall flatness deviation caused by the protrusions at the main deformation positions of the first and second honeycomb aluminum wall panels can be slightly adjusted by hammering the first and second columns.

[0025] Secondly, embodiments of the present invention also provide a honeycomb aluminum end wall, obtained by the honeycomb aluminum end wall manufacturing method described above.

[0026] Thirdly, the present invention also provides a rail vehicle, which includes the aforementioned honeycomb aluminum end wall.

[0027] The beneficial effects of the above embodiments of the present invention are as follows:

[0028] This invention addresses the problems of internal honeycomb structure melting, poor welding quality, and large post-weld deformation caused by thin welded joints in honeycomb aluminum structures by optimizing the assembly process, welding sequence, and segmented welding to reduce heat input. It also solves the problems of easy scratching and indentations on the honeycomb aluminum skin surface that cannot be repaired by grinding by rationally distributing tooling clamping and anti-deformation positions and increasing the contact area with the honeycomb aluminum wall panel. Furthermore, by adjusting the welding sequence, combined with tooling constraints and prefabrication expansion and anti-deformation, it solves the problems of post-weld shrinkage and torsional deformation of the honeycomb aluminum end walls, which reduce manufacturing precision, ensuring an overall flatness of no more than 3mm and a manufacturing precision of no more than ±2mm for important dimensions. This invention solves the problems of difficult manufacturing and low manufacturing precision of large honeycomb aluminum welded structures, providing conditions for the application of honeycomb aluminum wall panels in rail transportation and other industrial products. Attached Figure Description

[0029] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0030] Figure 1 This is a schematic diagram of the honeycomb aluminum end wall structure proposed in this invention;

[0031] Figure 2 This is a schematic diagram of the tooling clamping scheme in the welding process of the honeycomb aluminum end wall structure of the present invention;

[0032] Figure 3 This is a schematic diagram of the welding sequence proposed in this invention;

[0033] In the diagram: 1. First curved beam; 2. Second curved beam; 3. Third curved beam; 4. First honeycomb aluminum wall panel; 5. Second honeycomb aluminum wall panel; 6. Third honeycomb aluminum wall panel; 7. First column; 8. Second column; 9. First crossbeam; 10. Second crossbeam; 11. Third crossbeam; 12. First process support; 13. Second process support;

[0034] 20. Main deformation area after welding of honeycomb aluminum junction end wall; 30. Welding tool clamping device; 40. Clamping device with added nylon pads;

[0035] Welding sequence 1-1, 1-2, 1-3, 1-4, 1-5, 1-6, 1-7, 1-8, 1-9, 1-10, 1-11. Detailed Implementation

[0036] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0037] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0038] For ease of description, the words "up," "down," "left," and "right" appearing in this invention only indicate that they are consistent with the up, down, left, and right directions of the accompanying drawings themselves, and do not limit the structure. They are merely for the purpose of facilitating the description of this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0039] As described in the background section, there are shortcomings in the existing technology. In order to solve the above-mentioned technical problems, this invention proposes a method for manufacturing a honeycomb aluminum end wall, a honeycomb aluminum end wall, and a rail vehicle.

[0040] In a typical embodiment of the present invention, a method for manufacturing and precision control of a fully welded structure for railway train end walls, primarily composed of honeycomb aluminum wall panels, is provided, wherein the honeycomb aluminum end wall structure is as follows: Figure 1As shown, the structure includes a first curved beam 1, a second curved beam 2, a third curved beam 3, a first honeycomb aluminum wall panel 4, a second honeycomb aluminum wall panel 5, a third honeycomb aluminum wall panel 6, a first column 7, a second column 8, a first crossbeam 9, a second crossbeam 10, and a third crossbeam 11; among which, the first honeycomb aluminum wall panel 4, the second honeycomb aluminum wall panel 5, and the third honeycomb aluminum wall panel 6 are honeycomb aluminum wall panels, and the other components are aluminum profile structures; the first honeycomb aluminum wall panel 4 is welded to the first column 7, the first curved beam 1, the second curved beam 2, and the second crossbeam 10; the second honeycomb aluminum wall panel 5 is welded to the second column 8, the first curved beam 1, the third curved beam 3, and the third crossbeam 11; the third honeycomb aluminum wall panel 6 is welded to the first column 7, the second column 8, the first crossbeam 9, and the first curved beam 1, forming a complete honeycomb aluminum end wall; the specific welding steps are as follows:

[0041] Step 1: Place the first curved beam 1, the second curved beam 2, and the third curved beam 3 face up onto the welding fixture for assembly and welding. The existing welding fixture is used, so it will not be described in detail here.

[0042] Step 2: Place the first honeycomb aluminum wall panel 4, the second honeycomb aluminum wall panel 5, the first column 7, and the second column 8 face up onto the above-mentioned welding fixture. Then, place the third honeycomb aluminum wall panel 6 and the first crossbeam 9 face up onto the above-mentioned welding fixture. Finally, place the second crossbeam 10 and the third crossbeam 11 face up onto the above-mentioned welding fixture. At this point, all the components have been placed on the welding fixture.

[0043] Step 3: Adjust the outline dimensions of the end wall, with the width of the end wall based on the center line and the height of the end wall based on the bottom of the end wall; control the important dimensions such as the overall height, width, doorway width, and diagonal length difference of the end wall, and press all the above-mentioned curved beams, wall panels, columns, and beams tightly in sequence.

[0044] Step 4: Tack weld the weld seam on the front side of the end wall and install it. Figure 1 The first process support 12 and the second process support 13 shown in the figure control the dimensions between the first column 7 and the second column 8.

[0045] Step 5: Welding the front of the end wall.

[0046] Step 6: After the front weld has cooled, flip the end wall to the reverse assembly fixture with the reverse side of the workpiece facing up, and press the fixture tightly.

[0047] Step 7: Perform reverse welding.

[0048] Step 8: After the reverse weld has cooled, loosen the fixture, measure the dimensions, and if the dimensions are acceptable, grind the weld and accept it.

[0049] The manufacturing precision control in the above welding process is achieved through the following aspects:

[0050] First, when assembling from the front, allowances should be set in both the width and length directions to compensate for post-weld shrinkage deformation. The recommended allowance is 3mm-5mm.

[0051] Second, semi-automatic gas metal arc welding (automatic welding and non-gas metal arc welding are also acceptable) should be used for welding. When welding parameters ensure joint penetration, welding current should be reduced as much as possible to minimize heat input and welding deformation.

[0052] Third, the welding sequence used is as follows: Figure 3 As shown, Figure 3 This indicates the welding sequence only and does not represent the actual number of welded sections. Welding is performed first on the first honeycomb aluminum wall panel 4, the second honeycomb aluminum wall panel 5, and the first and second columns 7 and 8. The welding direction follows the height of the end wall from top to bottom, and welding is symmetrical on both sides. Each side is welded in three sections, with each section allowed to cool to room temperature before the previous section's weld is welded to avoid overheating the wall panel. For details, see [link to details]. Figure 3 The welding sequence is as follows: 1-1, 1-2, 1-3, where the same number indicates simultaneous welding; then, the third honeycomb aluminum wall panel 6 is welded to the first column 7, second column 8, first crossbeam 9, and first curved beam 1, following the welding sequence 1-4, 1-5, 1-6, where the same number indicates simultaneous welding; next, the first honeycomb aluminum wall panel 4, second honeycomb aluminum wall panel 5, first curved beam 1, second curved beam 2, and third curved beam 3 are welded, starting from the top center and working towards the bottom on both sides, with simultaneous welding on both sides, specifically following the welding sequence 1-7, 1-8, 1-9, where the same number indicates simultaneous welding; finally, the first honeycomb aluminum wall panel 4, second honeycomb aluminum wall panel 5, second crossbeam 9, and third crossbeam 10 are welded, starting from the center of the end wall and working towards both sides, specifically following the welding sequence 1-11.

[0053] Fourth, in this embodiment, the welding sequence on the reverse side of the end wall is the same as the welding sequence on the front side, and will not be repeated here.

[0054] Fifth, the clamping device should be kept away from direct contact with the first honeycomb aluminum wall panel 4, the second honeycomb aluminum wall panel 5, and the third honeycomb aluminum wall panel 6 to avoid irreversible surface indentations caused by excessive local pressure. The clamping device clamping scheme is as follows: Figure 2 As shown, clamping devices 30 are fixed on the first bend 1, the second bend beam 2, the third bend beam 3, the first column 7, the second column 8, and the first crossbeam 9. The clamping devices 30 can be general-purpose welding fixture clamping devices. Multiple clamping devices 30 are installed at certain intervals. Clamping devices 40 with added nylon pads are installed on the first honeycomb aluminum wall panel 4 and the second honeycomb aluminum wall panel 5. Figure 2In the process, two clamping devices 40 with added nylon pads are set near the outer edge of the first honeycomb aluminum wall panel 4 and two clamping devices 40 with added nylon pads are set near the outer edge of the second honeycomb aluminum wall panel 5. The clamping devices 40 with added nylon pads increase the contact area with the honeycomb aluminum wall panel through the nylon pads, thereby reducing the pressure. The four corners of the contact surface between the nylon pads and the honeycomb aluminum wall panel should be rounded to avoid damaging the honeycomb aluminum surface.

[0055] Fifth, in Figure 2 The honeycomb aluminum junction end wall shown in the diagram is prone to bulging towards the front after welding, resulting in overall flatness exceeding tolerances. Therefore, the reverse welding fixture must be equipped with anti-deformation features. Specifically, before reverse welding, 100mm wide aluminum alloy pads are used to raise the main deformation area and press them together on both sides to make the reverse side of the wall panel bulge. Figure 2 As shown, a long strip of aluminum alloy pad is installed on each of the first honeycomb aluminum wall panel 4 and the second honeycomb aluminum wall panel 5. The length and width of the aluminum alloy pad can be adjusted appropriately, but the width should not be less than 50mm to prevent indentations on the wall panel surface. The four corners of the contact surface between the aluminum alloy pad and the honeycomb aluminum wall panel should be rounded to avoid damaging the honeycomb aluminum surface.

[0056] Sixth, the overall flatness after welding should be controlled to be no more than 3mm, because Figure 2 The overall flatness deviation caused by the protrusion of the main deformation area 20 is too large. Therefore, after welding, it can be slightly adjusted by hammering the first column 7 and the second column 8. However, the honeycomb aluminum wall panel cannot be directly pressure-adjusted.

[0057] The aforementioned manufacturing method discloses a method for assembling, welding, and controlling the manufacturing precision of a railcar end wall with a fully welded structure, primarily composed of honeycomb aluminum wall panels. By optimizing the assembly process, welding sequence, adjusting welding parameters, and reducing heat input through segmented welding, the method addresses the problems of internal honeycomb structure melting, poor welding quality, and large post-weld deformation caused by thin welded joints in the honeycomb aluminum structure. Furthermore, by rationally distributing the tooling clamping and anti-deformation positions and increasing the contact area with the honeycomb aluminum wall panels, the method solves the problems of easy scratching and indentations on the honeycomb aluminum skin surface that cannot be repaired by grinding. Finally, by adjusting the welding sequence, and coordinating with tooling constraints and prefabrication expansion and anti-deformation, the method solves the problems of post-weld shrinkage and torsional deformation of the honeycomb aluminum end wall, leading to reduced manufacturing precision.

[0058] This invention solves the problems of difficult manufacturing and low manufacturing precision of large honeycomb aluminum welded structures, and provides conditions for the application of honeycomb aluminum panels in rail transportation and other industrial products.

[0059] Furthermore, this embodiment also provides a honeycomb aluminum end wall manufactured by the above-described manufacturing method. Since the honeycomb aluminum end wall is manufactured by the above-described method, its overall flatness is no greater than 3mm, and the manufacturing accuracy of important dimensions is no greater than ±2mm.

[0060] Furthermore, this embodiment also provides a rail vehicle whose end wall is obtained by the above-described manufacturing method. Of course, the rail vehicle mentioned here can be any suitable type of vehicle, such as conventional trains, high-speed trains, subway vehicles, urban rail vehicles, etc. The present invention is not limited to a certain type or certain specific rail vehicle.

[0061] Finally, it should be noted that relational terms such as first and second are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0062] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing a honeycomb aluminum end wall, wherein the honeycomb aluminum end wall comprises a first curved beam, a second curved beam, a third curved beam, a first honeycomb aluminum wall panel, a second honeycomb aluminum wall panel, a third honeycomb aluminum wall panel, a first column, a second column, a first crossbeam, a second crossbeam, and a third crossbeam, characterized in that, The manufacturing steps are as follows: The first, second, and third curved beams are placed face up on the welding fixture for assembly and welding. Place the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel, the first column, and the second column face up onto the welding fixture in sequence. Then place the third honeycomb aluminum wall panel and the first crossbeam face up onto the welding fixture in sequence. Finally, place the second crossbeam and the third crossbeam face up onto the welding fixture in sequence. Adjust the dimensions of the end wall outline, using the center line as the reference in the width direction and the bottom of the end wall as the reference in the height direction, and then press all the curved beams, wall panels, columns, and crossbeams together in sequence. Tack weld the weld seam on the front of the end wall, and install process supports to control the dimensions before welding the front of the end wall. During the front welding process, the first honeycomb aluminum wall panel and the first and second columns are welded first, then the third honeycomb aluminum wall panel and the first column, the second column, and the first crossbeam are welded. Then the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel and the first curved beam, the second curved beam, and the third curved beam are welded. Finally, the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel, the second crossbeam, and the third crossbeam are welded. After the front weld has cooled, flip the end wall to the reverse assembly fixture with the reverse side of the workpiece facing up, tighten the fixture, and perform reverse welding.

2. The method for manufacturing honeycomb aluminum end walls as described in claim 1, characterized in that, When assembling from the front, allowances should be set for assembly in both the width and length directions.

3. The method for manufacturing honeycomb aluminum end walls as described in claim 1, characterized in that, The welding direction of the first, honeycomb aluminum wall panel and the first and second columns is from top to bottom, and the welding is carried out in three sections. Each section is welded after the weld of the previous section has cooled to room temperature; and the welding on both sides is carried out simultaneously.

4. The method for manufacturing honeycomb aluminum end walls as described in claim 1, characterized in that, The welding of the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel, the first curved beam, the second curved beam, and the third curved beam is carried out from the top center to the bottom of both sides, with simultaneous welding on both sides.

5. The method for manufacturing honeycomb aluminum end walls as described in claim 1, characterized in that, The welding of the first honeycomb aluminum wall panel, the second honeycomb aluminum wall panel, the second crossbeam, and the third crossbeam is performed from the center outwards to both sides.

6. The method for manufacturing honeycomb aluminum end walls as described in claim 1, characterized in that, The clamping devices are fixed on the first curved beam, the second curved beam, the third curved beam, the first column, the second column, and the first crossbeam.

7. The method for manufacturing honeycomb aluminum end walls as described in claim 6, characterized in that, Multiple clamping devices are provided, spaced at certain intervals.

8. The method for manufacturing honeycomb aluminum end walls as described in claim 1, characterized in that, A clamping device with added nylon pads is installed on the first and second honeycomb aluminum wall panels.

9. The method for manufacturing a honeycomb aluminum end wall as described in claim 8, characterized in that, The four corners of the contact surface between the nylon pad and the honeycomb aluminum wall panel should be rounded.

10. The method for manufacturing a honeycomb aluminum end wall as described in claim 1, characterized in that, Before welding the reverse side, pads are used to lift the main deformation positions of the first and second honeycomb aluminum wall panels and press them together on both sides to make the reverse side of the wall panels convex.

11. The method for manufacturing honeycomb aluminum end walls as described in claim 1, characterized in that, The overall flatness deviation caused by the protrusions at the main deformation locations of the first and second honeycomb aluminum wall panels was slightly adjusted by hammering the first and second columns.

12. A honeycomb aluminum end wall, characterized in that, Obtained by the method for manufacturing the honeycomb aluminum end wall according to any one of claims 1-11.

13. A rail vehicle, characterized in that, The end walls of the rail vehicle body are made of the honeycomb aluminum end walls as described in claim 12.

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