Welding straightening methods and manufacturing methods for rail vehicle wall panels

Abstract

This invention provides a welding straightening method and a method for manufacturing rail vehicle wall panels. The straightening method applies to overlapping upper and lower plates, wherein the upper plate is fully fused at the weld, and the lower plate is partially fused at the weld. The straightening method includes: applying a tensile force towards the outside of the lower plate on both sides along a direction perpendicular to the weld; and irradiating the unfused side of the lower plate with a laser of predetermined power along the weld. This invention achieves the effect of correcting deformation by applying a tensile force to the lower plate while simultaneously irradiating the unfused side with a laser to induce metal shrinkage deformation.

Description

Technical Field

[0001] This invention relates to the field of rail vehicle manufacturing technology, and in particular to a welding straightening method and a method for manufacturing rail vehicle wall panels. Background Technology

[0002] Since stainless steel car bodies are mostly unpainted, laser welding of stainless steel car bodies in the rail vehicle industry often adopts a semi-penetration type, meaning that only part of the lower plate is welded through. The laser weld morphology is wider at the top and narrower at the bottom, which leads to uneven distribution of various stresses in the weld and surrounding heated areas along the thickness of the plate. This causes a change in the relative angle between the metal plates on both sides of the weld, resulting in angular deformation. The occurrence of angular deformation causes a micro-protrusion corresponding to the weld to appear on the side wall plate, affecting the visual appearance of the car body.

[0003] Therefore, it is necessary to eliminate the raised marks caused by the aforementioned angular deformation.

[0004] The information disclosed in this background section is intended only to enhance the understanding of the general background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0005] In view of the problems existing in the prior art, the present invention provides a welding straightening method and a method for manufacturing rail vehicle wall panels.

[0006] The present invention provides a welding straightening method, wherein the straightening method applies to overlapping upper and lower plates, wherein the upper plate is fully welded at the weld seam, and the lower plate is partially welded at the weld seam. The straightening method includes:

[0007] Tensile force is applied to both sides of the lower plate in a direction perpendicular to the weld, moving outwards from the plate.

[0008] A laser of predetermined power is irradiated along the weld seam on the side of the lower plate that has not been fully melted.

[0009] Optionally, along a direction perpendicular to the weld, a tensile force is applied to both sides of the lower plate toward the outer side of the plate, including:

[0010] The lower plate is flattened so that it fits into the work platform, which supports the lower plate.

[0011] Optionally, the lower plate can be stacked with multiple parallel upper plates to serve as wall panels for the body of a rail vehicle.

[0012] Optionally, the operating parameters of the laser include at least one of the following:

[0013] The laser power is 0.1–5kW, the laser moving speed is 1–10m / min, the defocusing amount is +3–40mm, and the spot diameter is ≥0.3mm.

[0014] Optionally, the operating parameters of the laser shall satisfy at least one of the following three states;

[0015] First state: laser power is 0.1kW, laser moving speed is 1m / min, defocusing amount is +3mm, and spot diameter is 0.3mm;

[0016] Second state: laser power is 2kW, laser moving speed is 3m / min, defocusing amount is +15mm, and spot diameter is 2mm;

[0017] Third state: laser power is 5kW, laser moving speed is 10m / min, defocusing amount is +40mm, and spot diameter is 5mm.

[0018] Optionally, the orthopedic method further includes:

[0019] The oxidized and discolored areas of the lower plate after correction were cleaned using an electrochemical method.

[0020] The present invention also provides a method for manufacturing a rail vehicle wall panel, wherein the rail vehicle wall panel includes a lower plate on which multiple parallel upper plates are simultaneously stacked, the rail vehicle wall panel includes a first region, and the manufacturing method includes:

[0021] The welding straightening method described above is used to straighten the lower plate in the first region;

[0022] After the straightening is completed, a film is applied to the side of the lower plate in the first area that has not been melted through.

[0023] Optionally, the rail vehicle wall panel further includes a second region, and the manufacturing method further includes:

[0024] The side of the lower plate in the second region that was not fully melted was subjected to wire drawing.

[0025] The technical solution of the present invention also provides a rail vehicle wall panel, which is manufactured using the rail vehicle wall panel manufacturing method described above.

[0026] The present invention also provides a rail vehicle, including the aforementioned rail vehicle wall panel.

[0027] The present invention also provides a welding straightening device for overlapping upper and lower plates, wherein the upper plate is fully welded at the weld seam and the lower plate is partially welded at the weld seam. The device comprises:

[0028] A tensioning module is used to apply a tensioning force toward the outside of the plate on both sides of the lower plate along a direction perpendicular to the weld.

[0029] A laser module is used to irradiate the weld seam with a predetermined power along the side of the lower plate that has not been fully melted.

[0030] The welding straightening method and the manufacturing method of rail vehicle wall panels provided by the present invention achieve the effect of correcting deformation by applying tensile force to the lower plate and simultaneously irradiating the un-melted side with laser to achieve metal shrinkage deformation. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0032] Figure 1 This is a schematic flowchart of a welding straightening method provided in an embodiment of the present invention;

[0033] Figure 2 A top and side view schematic diagram of the tensioning of a rail vehicle wall panel provided in an embodiment of the present invention;

[0034] Figure 3 This is a schematic diagram of a welding straightening device provided in an embodiment of the present invention;

[0035] Figure 4 This is a schematic diagram of the physical structure of an electronic device provided by the present invention. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0037] The welding straightening method provided in this application will be described in detail below with reference to the accompanying drawings, through specific embodiments and application scenarios.

[0038] In one embodiment, the corner deformation of the side wall panels (corresponding to the lower plate) and beams (each beam has two side flanges corresponding to the upper plate) caused by the semi-penetration laser welding of the side wall panels (corresponding to the lower plate) of the rail vehicle can be small. Although the corner deformation of a single weld is small, the entire lower plate can have up to 20 welds. The cumulative corner deformation and the internal stress in the outer plate are large, which will lead to obvious protrusion marks on the surface of the lower plate and have a significant impact on the appearance. Therefore, the following welding correction method can be used to improve the visual effect of the appearance, which is applicable to the entire spectrum of stainless steel rail vehicle products.

[0039] Figure 1 This is a flowchart illustrating a welding straightening method provided in an embodiment of the present invention, as shown below. Figure 1 As shown, the technical solution of the present invention provides a welding straightening method. The object of the straightening method is an overlapping upper plate and a lower plate, wherein the upper plate is fully fused at the weld and the lower plate is partially fused at the weld. The straightening method includes the following steps:

[0040] S100. Apply tensile force towards the outside of the plate on both sides of the lower plate along the direction perpendicular to the weld.

[0041] S200. On the side of the lower plate that has not been fully melted, a laser of predetermined power is irradiated along the weld seam.

[0042] It should be noted that if the tension of S100 is not used and the laser is directly irradiated, the stress and deformation of the adjacent weld seam will act as an external force, which will indirectly affect the deformation direction of the outer plate, resulting in unstable angular deformation correction effect.

[0043] Optionally, along a direction perpendicular to the weld, a tensile force is applied to both sides of the lower plate toward the outer side of the plate, including:

[0044] Flatten the lower plate so that it fits snugly against the work platform, which then supports the lower plate.

[0045] Optionally, the lower plate can be stacked with multiple parallel upper plates to serve as wall panels for the rail vehicle body.

[0046] Optionally, the laser's operating parameters shall include at least one of the following:

[0047] The laser power is 0.1–5 kW, the laser movement speed is 1–10 m / min, the defocusing amount is +3–40 mm, and the spot diameter is ≥0.3 mm. Under these operating parameters, good correction effect and correction efficiency can be obtained.

[0048] Preferably, in one embodiment, the laser power is 0.1kW, the laser moving speed is 1m / min, the defocusing amount is +3mm, and the spot diameter is 0.3mm; the correction of the plate with a narrow deformation area is achieved by using a relatively small power.

[0049] Preferably, in one embodiment, the laser power is 2kW, the laser moving speed is 3m / min, the defocusing amount is +15mm, and the spot diameter is 2mm; correction is achieved through a compromise of power.

[0050] Preferably, in one embodiment, the laser power is 5kW, the laser moving speed is 10m / min, the defocusing amount is +40mm, and the spot diameter is 5mm; the higher power enables the correction of plates with larger deformation areas, or enables faster correction.

[0051] Furthermore, in one embodiment, the operating parameters of the laser include:

[0052] The laser power is 0.7kW, the laser moving speed is 3-5m / min, the defocusing amount is +20mm, and the spot diameter is ≥2mm.

[0053] Furthermore, in one embodiment, to avoid the influence of angular deformation and internal stress of adjacent welds, a tensile force F is added to both sides in the direction perpendicular to the weld. The single-point tensile force F = (6-10)t, and the specific size and arrangement are determined according to the condition of the lower plate. This eliminates the angular deformation accumulated on the component. Before straightening, the wall plate is flattened to fit with the working platform, which is conducive to the control of straightening parameters such as defocusing amount. An external tensile stress is applied to the straightened weld area, that is, mechanical straightening is added at the same time as laser thermal straightening to improve the straightening efficiency and effect. The process specifications of laser power P = 0.7kW, speed v = 3m / min, and defocusing amount f = +20mm are adopted, and the effect can be achieved in one straightening. The external tensile stress offsets the influence of stress and deformation of adjacent welds on the outer plate during the laser straightening process, and guides and standardizes the direction and consistency of laser welding thermal straightening.

[0054] This embodiment uses the aforementioned method to eliminate angular deformation marks on the back of the lower plate, greatly improving the overall commercial quality of the stainless steel exposed wall panel of the vehicle body; because laser has concentrated energy density and is easy to achieve precise control, it is suitable for repairing minor deformations; it can precisely control the heat straightening temperature without damaging the surface appearance of the wall panel, achieving traceless heat straightening; the equipment used for welding and straightening is consistent, reducing the number of workstations required, thereby effectively controlling manufacturing costs.

[0055] Alternatively, the orthopedic method may also include:

[0056] The oxidized and discolored areas after the lower plate was corrected were cleaned using an electrochemical method. This electrochemical cleaning process removed the traces of oxidation and discoloration from the corrected areas.

[0057] Furthermore, in one embodiment, since the area directly affected by the laser energy is the surface area of ​​the workpiece, the incident angle has little impact on the straightening effect, so vertical incidence is adopted;

[0058] Given that the width of the laser-welded deformation area is about 2mm, in order to ensure uniform and sufficient correction, the spot diameter D is ≥2mm and the corresponding defocusing amount is +20mm. To ensure the efficiency of laser correction while taking into account the appearance of the wall panel, the laser power P = 0.7kW and the correction speed v = 5m / min. After the correction is completed, electrochemical cleaning is used to remove the oxidation and discoloration marks in the correction area.

[0059] It should be noted that the raised line marks on the lower plate produced by laser welding are about 0.3mm high. For a specific appearance effect, some wall panels need to be coated with a glossy film. The mirror reflection after the film is applied magnifies the welding marks and greatly reduces the appearance of the vehicle. Therefore, it is particularly important to correct the small angular deformation of non-penetrating laser overlay welds by combining low-power laser and tensioning. This is especially important for the wall panels of rail vehicles that need to be coated.

[0060] In another embodiment, the technical solution of the present invention also provides a method for manufacturing a rail vehicle wall panel, the rail vehicle wall panel including a lower plate with multiple parallel upper plates stacked on top of each other, the rail vehicle wall panel including a first region, and the manufacturing method including:

[0061] The welding straightening method used is used to straighten the lower plate in the first region;

[0062] After the straightening is completed, the side of the lower plate in the first area that has not been melted through is covered with a film.

[0063] Optionally, the rail vehicle wall panel also includes a second region, and the manufacturing method further includes:

[0064] The side of the lower plate in the second area that was not fully melted was subjected to wire drawing.

[0065] It should be noted that for areas that do not require coating, a brushing process is applied directly to the metal plate to create a scattering surface, making the raised lines less noticeable and thus improving the appearance.

[0066] Figure 2 This invention provides top and side views of the tensioning of a rail vehicle wall panel, as shown in the embodiments of the present invention. Figure 2 As shown, this is a side wall panel of a rail vehicle containing windows. The side wall panel has multiple beams and columns. The part selected by the dashed line will eventually need to be covered with a film. Therefore, this area is the first area mentioned above, and the other areas are the second area. The welds in the first area are straightened, and the second area is wire drawn to improve the appearance while improving efficiency and economy.

[0067] The technical solution of the present invention also provides a rail vehicle wall panel, which is manufactured using a rail vehicle wall panel manufacturing method.

[0068] The technical solution of the present invention also provides a rail vehicle, including rail vehicle wall panels.

[0069] The welding straightening device provided by the present invention is described below. The welding straightening device described below and the welding straightening method described above can be referred to in correspondence.

[0070] Figure 3 This is a schematic diagram of a welding straightening device provided in an embodiment of the present invention, as shown below. Figure 3 As shown, the technical solution of the present invention also provides a welding straightening device, which is designed for overlapping upper and lower plates, wherein the upper plate is fully fused at the weld and the lower plate is partially fused at the weld. The device includes:

[0071] Tensioning module, used to apply tension force towards the outside of the plate on both sides of the lower plate in a direction perpendicular to the weld;

[0072] The laser module is used to irradiate the weld seam with a predetermined power on the side of the lower plate that has not been fully melted.

[0073] This embodiment achieves the effect of correcting deformation by applying tensile force to the lower plate and simultaneously irradiating the unmelted side with a laser to induce metal shrinkage and deformation.

[0074] Figure 4 A schematic diagram of the physical structure of an electronic device provided by the present invention, such as... Figure 4 As shown, the electronic device may include: a processor 810, a communication interface 820, a memory 830, and a communication bus 840, wherein the processor 810, the communication interface 820, and the memory 830 communicate with each other through the communication bus 840. The processor 810 can call logical instructions in the memory 830 to execute a welding straightening method. The straightening method targets overlapping upper and lower plates, wherein the upper plate is fully fused at the weld seam, and the lower plate is partially fused at the weld seam. The straightening method includes:

[0075] Tensile force is applied to both sides of the lower plate in a direction perpendicular to the weld, moving outwards from the plate.

[0076] A laser of predetermined power is irradiated along the weld seam on the side of the lower plate that has not been fully melted.

[0077] Furthermore, the logical instructions in the aforementioned memory 830 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, essentially, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0078] On the other hand, the present invention also provides a computer program product, the computer program product comprising a computer program stored on a non-transitory computer-readable storage medium, the computer program comprising program instructions, wherein when the program instructions are executed by a computer, the computer is able to execute the welding straightening method provided by the above methods, the straightening method being applied to overlapping upper and lower plates, the upper plate being fully penetrated at the weld, and the lower plate being partially penetrated at the weld, the straightening method comprising:

[0079] Tensile force is applied to both sides of the lower plate in a direction perpendicular to the weld, moving outwards from the plate.

[0080] A laser of predetermined power is irradiated along the weld seam on the side of the lower plate that has not been fully melted.

[0081] In another aspect, the present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the welding straightening methods provided above, wherein the straightening method applies to overlapping upper and lower plates, the upper plate being fully penetrated at the weld and the lower plate being partially penetrated at the weld, and the straightening method includes:

[0082] Tensile force is applied to both sides of the lower plate in a direction perpendicular to the weld, moving outwards from the plate.

[0083] A laser of predetermined power is irradiated along the weld seam on the side of the lower plate that has not been fully melted.

[0084] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0085] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus necessary general-purpose hardware platforms, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or some parts of the embodiments.

[0086] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A welding straightening method, wherein the method is applied to overlapping upper and lower plates, wherein the upper plate is fully welded at the weld joint, and the lower plate is partially welded at the weld joint, characterized in that, The orthopedic method includes: Along a direction perpendicular to the weld, tensile forces are applied to both sides of the lower plate toward the outside of the plate; the lower plate is a side wall plate of a rail vehicle, and the upper plate is a side wing plate of a beam or column; On the side of the lower plate that is not fully melted, a laser of predetermined power is irradiated along the weld; the operating parameters of the laser include at least one of the following: laser power, laser movement speed, defocusing amount, and spot diameter; Also includes: The oxidized and discolored areas after the lower plate was shaped were cleaned using an electrochemical method.

2. The welding straightening method according to claim 1, characterized in that, Applying tensile forces toward the outer side of the lower plate along a direction perpendicular to the weld seam, including: The lower plate is flattened so that it fits into the work platform, which supports the lower plate.

3. The welding straightening method according to claim 2, characterized in that, The lower plate is simultaneously stacked with multiple parallel upper plates to serve as wall panels for the rail vehicle body.

4. The welding straightening method according to claim 3, characterized in that, The operating parameters of the laser include at least one of the following: The laser power is 0.1~5kW, the laser moving speed is 1~10m / min, the defocusing amount is +3~40mm, and the spot diameter is ≥0.3mm.

5. The welding straightening method according to claim 4, characterized in that, The operating parameters of the laser must satisfy at least one of the following three states; First state: laser power is 0.1kW, laser moving speed is 1m / min, defocusing amount is +3mm, and spot diameter is 0.3mm; Second state: laser power is 2kW, laser moving speed is 3m / min, defocusing amount is +15mm, and spot diameter is 2mm; Third state: laser power is 5kW, laser moving speed is 10m / min, defocusing amount is +40mm, and spot diameter is 5mm.

6. A method for manufacturing a rail vehicle wall panel, wherein the rail vehicle wall panel comprises a lower plate on which multiple parallel upper plates are simultaneously stacked, characterized in that, The rail vehicle wall panel includes a first region, and the manufacturing method includes: The lower plate in the first region is straightened using any of the welding straightening methods described in claims 1-5; After the straightening is completed, a film is applied to the side of the lower plate in the first area that has not been melted through.

7. The method for manufacturing a rail vehicle wall panel according to claim 6, characterized in that, The rail vehicle wall panel further includes a second region, and the manufacturing method further includes: The side of the lower plate in the second region that was not fully melted was subjected to wire drawing.

8. A wall panel for a rail vehicle, characterized in that, The rail vehicle wall panel is manufactured using the rail vehicle wall panel manufacturing method described in claim 6 or 7.

9. A rail vehicle, characterized in that, Includes the rail vehicle wall panel as described in claim 8.

10. A welding straightening device, wherein the device is applied to overlapping upper and lower plates, the upper plate being fully fused at the weld joint and the lower plate being partially fused at the weld joint, characterized in that, The device includes: A tensioning module is used to apply a tensioning force toward the outside of the plate on both sides of the lower plate along a direction perpendicular to the weld; the lower plate is a side wall plate of a rail vehicle, and the upper plate is a side wing plate of a beam or column; A laser module is used to irradiate the weld seam with a predetermined power along the side of the lower plate that has not been fully melted; the operating parameters of the laser include at least one of the following: laser power, laser moving speed, defocusing amount, and spot diameter. Also includes: The oxidized and discolored areas after the lower plate was shaped were cleaned using an electrochemical method.

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