A manufacturing method for a large box girder of a vehicle frame

Abstract

A manufacturing method for a large box girder of a vehicle frame is provided, belonging to the technical field of box girder manufacturing. The box girder is formed by welding two vertical plates, a lower cover plate, an upper cover plate and a plurality of partition plates; specifically including the following steps: tooling preparation; blanking: a deflection is prefabricated in the middle part of the vertical plate during blanking; manufacturing the deflection of the lower cover plate; welding the vertical plate, the lower cover plate and the partition plates; welding the inner welds of the box girder; spot-fixing the upper cover plate; welding the outer welds of the box girder; grinding. In the manufacturing process of the box girder of the present invention, convenient tooling is made, the material quality and assembly gap are strictly required, and the welding parameters and welding sequence are optimized to ensure that the finished product of this box girder meets the requirements of the drawings, solve the problem of difficult manufacturing of large-deflection and large box girders widely used in rail vehicles and large track maintenance machinery, and improve the operation level of workshop workers.

Description

Technical Field

[0001] The present invention belongs to the technical field of box girder manufacturing, and particularly relates to a manufacturing method for a large box girder of a vehicle frame. Background Art

[0002] A large box girder of a vehicle frame has a length of about 24810 mm, a maximum cross-section of 950*900 mm, a minimum cross-section of 340*900 mm, a maximum plate thickness of 40 mm, and a weight of about 20 tons. It belongs to a variable cross-section box girder, that is, a box girder in the form of a fish-belly beam, as Figure 9 shown. The deflection requirement for the box girder is 40 - 50 mm, the lateral bending is not more than 5 mm, and the straightness is not more than 5 mm. The existing box girder manufacturing tooling in the workshop has dimensions of 200*300*16000, and the conventional box girder plate thickness is between 10 - 20 mm. The deflection value is approximately between 10 - 25 mm. The deflection manufacturing method mainly relies on the welding deformation of the vehicle frame to achieve. The existing manufacturing method has the following problems: First, the welding amount is large and it is difficult to control the welding deformation; second, the box girder has a large stiffness, a large required deflection value, and it is difficult to manufacture the deflection. In view of the problems existing in the prior art, improvements are thus proposed. Summary of the Invention

[0003] The technical problem solved by the present invention: Provide a manufacturing method for a large box girder of a vehicle frame. The main purpose of the present invention is to solve the problems of large welding amount and difficult control of welding deformation of the fish-belly type large box girder, large stiffness of the box girder, large required deflection value, and difficult manufacture of the deflection.

[0004] To achieve the above object, the technical solution adopted by the present invention:

[0005] A manufacturing method for a large box girder of a vehicle frame. The box girder is formed by group welding two vertical plates, one lower cover plate, one upper cover plate, and multiple partition plates; specifically includes the following steps:

[0006] (1) Tooling preparation: Manufacture multiple side positioning toolings, multiple upper support toolings, and two lower support toolings, and prepare multiple cushion blocks, multiple pressing blocks, multiple side positioning jacks, multiple upper positioning jacks, and various specifications of backing plates;

[0007] (2) Blanking: Blank according to the dimensional requirements of the vertical plates, lower cover plate, upper cover plate, and partition plates. When blanking the vertical plates, prefabricate the deflection in the middle part;

[0008] (3) Deflection manufacturing of the lower cover plate: Uniformly distribute and fix multiple side positioning toolings in a row on the left side of the working platform. One long side of the lower cover plate is closely attached to the multiple side positioning toolings on the left side. The two lower parts of the two ends of the lower cover plate are supported by the lower support toolings. The middle part of the lower cover plate is lifted by multiple backing plates of different specifications to a corresponding height to match the deflection of the vertical plates to manufacture the deflection. The two ends in the middle part of the lower cover plate are both pressed tightly by the pressing blocks;

[0009] (4) Welding of vertical plates, lower cover plates and partition plates: Adjust the straightness and perpendicularity of the side positioning tooling on the left side. Taking the side positioning tooling on the left side as the reference, position the vertical plates and partition plates on the left side in combination with the cushion blocks, and tack the vertical plates and partition plates on the left side. Use a square to ensure that the perpendicularity between the vertical plate and the partition plate is not more than 1 mm. Then, position the vertical plate on the right side with the partition plate and the lower cover plate, and use multiple side positioning toolings and side positioning jacks on the right side to press and hold the vertical plate on the right side to ensure the perpendicularity of the vertical plate and the opening dimension between the two vertical plates, and tack the vertical plate and the partition plate on the right side. When tacking the partition plates, tack from the middle to both sides.

[0010] (5) Welding of the inner welds of the box girder: Keep the box girder in the position of the previous process unchanged. The welds between the partition plates and the vertical plates are welded by vertical welding, and the welding sequence is to weld from the middle to both sides simultaneously.

[0011] (6) Tack welding of the upper cover plate: After hoisting the upper cover plate to the box girder by using a crane, finely adjust the dimensions in the front, back, left and right directions to meet the requirements of the drawing. When the gap between the upper cover plate and the vertical plate is ≥ 3 mm, use the upper positioning jack and the upper support tooling to press and hold, and then tack from the middle of the vehicle frame to both sides.

[0012] (7) Welding of the outer welds of the box girder: Remove the side positioning tooling on one side, use a crane to turn the box girder 90°, and four people weld from the middle of the vehicle frame to both ends simultaneously. Adopt multi-layer continuous welding, and clean the welding slag and surface spatter in time after each layer of weld bead is welded.

[0013] (8) Grinding: After welding, tidy up and grind to clean the welding slag and spatter.

[0014] In the above step (2), the prefabricated deflection value of the vertical plate during blanking is 50 mm, and the deflection production range is at the middle straight section that cooperates with the lower cover plate.

[0015] In the above step (2), the vertical plate, the lower cover plate and the upper cover plate are respectively composed of three pieces of plates spliced together. Among them, to prevent bending deformation at the splicing place, the lower cover plate and the upper cover plate are spliced with 40 mm thick plates and completed by the welding method of less welding and more turning over; the vertical plate is spliced with 20 mm conventional plates, and the splicing place is pressed and held by combining the side positioning tooling and the upper support tooling with the upper positioning jack and the pressing block.

[0016] In the above step (3), one side of the lower cover plate is closely attached to the side positioning tooling to ensure straightness. Taking the center of the lower cover plate as the reference, pads of 30 * 900 mm are respectively placed at the center of the lower cover plate and at positions 2500 mm and 5000 mm away from the center, with thicknesses of 50 mm, 42 mm and 22 mm respectively; at points a and b at the bending place of the lower cover plate, use the pressing block to press and hold the lower cover plate and the platform to prevent the lower cover plate from causing deformation of the box girder.

[0017] In the above step (1), each of the side positioning tools includes two vertically arranged columns. The lower ends of the two columns are connected by a lower cross beam, the upper ends of the two columns are connected by an upper cross beam, the two columns are connected by a diagonal beam, and the inside of the columns is strengthened and connected by rib plates. A hole is provided at the upper end of the column for the end of the upper support tool to pass through for positioning.

[0018] In the above step (1), the upper support tool is formed by symmetrically buckling and connecting two channel steels, and the two channel steels are connected by internal rib plates.

[0019] In the above step (1), the lower support tool includes upper and lower cover plates that are parallel to each other and correspond up and down, and the upper and lower cover plates are connected by a plurality of support ribs.

[0020] Advantages of the present invention compared with the prior art:

[0021] This solution aims at the two major difficulties of controlling welding deformation and manufacturing deflection in the manufacturing of large frame box girders. During the manufacturing process of the box girder, tools that are convenient for manufacturing are made, namely side positioning tools, upper support tools, and lower support tools. The quality of materials and assembly gaps are strictly required, and welding parameters and welding sequences are optimized to ensure that the finished product of this box girder meets the requirements of the drawings, solve the problem of difficult manufacturing of large deflection and large box girders widely used in rail vehicles and large track maintenance machinery, and ensure product quality. The successful manufacturing of this box girder improves the operation level of workshop workers, enriches the on-site experience of process personnel and workshop workers, and lays a foundation for the subsequent manufacturing of other large steel structures. Brief Description of the Drawings

[0022] Figure 1 is the process flow chart of the present invention;

[0023] Figure 2 is the front view of the side positioning tool in the present invention;

[0024] Figure 3 is the left view of the side positioning tool in the present invention;

[0025] Figure 4 is the top view of the side positioning tool in the present invention;

[0026] Figure 5 is the front view of the lower support tool in the present invention;

[0027] Figure 6 is the top view of the lower support tool in the present invention;

[0028] Figure 7 is the front view of the upper support tool in the present invention;

[0029] Figure 8 is the left view of the upper support tool in the present invention;

[0030] Figure 9 Schematic diagram for blanking of the vertical plate in the present invention;

[0031] Figure 10 Welding sequence diagram for the splicing welds of the upper and lower cover plates in the present invention;

[0032] Figure 11 Welding sequence diagram for the splicing welds of the vertical plate in the present invention;

[0033] Figure 12 Schematic diagram for manufacturing the deflection of the lower cover plate in the present invention;

[0034] Figure 13 Front view of the welding and assembly process in the present invention;

[0035] Figure 14 Top view of the welding and assembly process in the present invention;

[0036] Figure 15 In the present invention Figure 14 Schematic diagram of the structure in the B - B direction;

[0037] Figure 16 Schematic diagram of the welding sequence for the inner welds of the box girder in the present invention;

[0038] Figure 17 Schematic diagram of the welding sequence for the outer welds of the box girder in the present invention. Detailed implementation manners

[0039] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present invention.

[0040] It should be noted that in this article, the term "comprising", "including" or any other variant thereof is intended to cover non - exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device. Without further limitations, the element defined by the statement "including one..." does not exclude the existence of additional identical elements in the process, method, article or device including the said element.

[0041] Please refer to Figure 1-17 , and details of the embodiments of the present invention will be described.

[0042] A method for manufacturing a large box beam for a vehicle frame. This embodiment is described by taking a large box beam for a vehicle frame with a length of about 24810mm, a maximum cross-section of 950*900mm, a minimum cross-section of 340*900mm, a maximum plate thickness of 40mm, and a weight of about 20 tons, which belongs to a variable cross-section box beam, i.e., a fish belly beam type box beam. The structure of the box beam is welded by two vertical plates 1, a lower cover plate 2, an upper cover plate 3, and a plurality of partition plates 4. For the process flow of box beam manufacturing, please refer to Figure 1 As shown, the specific steps include:

[0043] (1) Tool preparation: Make multiple side positioning tools 5, multiple upper support tools 6 and two lower support tools 7, and prepare multiple cushion blocks 8, multiple pressure blocks 9, multiple side positioning jacks 10, multiple upper positioning jacks 11 and pads 12 of various specifications.

[0044] The side positioning tooling 5, the lower supporting tooling 7 and the upper supporting tooling 6 are designed and manufactured according to the T-shaped platform used and the on-site conditions.

[0045] Specific reference Figures 2-4 As shown, each of the side positioning tools 5 includes two vertically erected columns 5-1, the lower ends of the two columns 5-1 are connected by a lower crossbeam 5-4, the upper ends of the two columns 5-1 are connected by an upper crossbeam 5-2, the two columns 5-1 are connected by an inclined beam 5-3, and the interior of the columns 5-1 is reinforced by a rib plate 5-5; the upper end of the column 5-1 is provided with a hole for the end of the upper supporting tool 6 to pass through for positioning.

[0046] Specific reference Figures 7-8 As shown, the upper supporting fixture 6 is formed by two channel steels 6-1 symmetrically interlocked and connected, and the two channel steels 6-1 are connected by an inner rib plate 6-2.

[0047] Specific reference Figures 5-6 As shown, the lower supporting tooling 7 includes upper and lower cover plates 7-1 which are parallel to each other and correspond to each other, and the upper and lower cover plates 7-1 are connected by a plurality of supporting ribs 7-2.

[0048] (2) Cutting: Cut the materials according to the dimensions required by the drawings of the vertical plate 1, the lower cover plate 2, the upper cover plate 3 and the partition plate 4. The vertical plate 1 is prefabricated with deflection in the middle part when cutting the materials. The prefabricated deflection value of the vertical plate 1 when cutting the materials is 50 mm. The deflection manufacturing range is the middle straight line segment matching the lower cover plate 2. See Figure 9 Shaded part.

[0049] Since the total length of the box girder in this embodiment exceeds 24000 mm and is limited by the length limit of the purchased plates (12000 mm), each vertical plate and cover plate is spliced from plates. The quality of the spliced vertical plates and cover plates directly affects the forming quality of the box girder. Therefore, when splicing the cover plates and vertical plates, to prevent bending deformation at the splicing joints, the requirements are as follows: The vertical plate 1, the lower cover plate 2, and the upper cover plate 3 are respectively spliced from three plates. The lower cover plate 2 and the upper cover plate 3 are spliced with 40-mm-thick plates, and welding is carried out strictly in accordance with the welding sequence. The welding is completed in the welding method of less welding and more turning over. It is strictly prohibited to complete the welding at one time. The welding sequence is as shown in 10. The vertical plate 1 is spliced with 20-mm conventional plates. When splicing, it is carried out in accordance with Figure 11 the welding sequence. At the splicing joints, the side positioning tooling 5 and the upper support tooling 6 are combined with the upper positioning jack 11 and the pressing block 9 to clamp tightly.

[0050] (3) Deflection production of the lower cover plate 2: A plurality of side positioning toolings 5 are uniformly arranged in a row and fixed on the left side of the working platform. One long side of the lower cover plate 2 abuts closely against the plurality of side positioning toolings 5 on the left side. The lower parts at both ends of the lower cover plate 2 are supported by the lower support tooling 7. The middle part of the lower cover plate 2 is lifted by a plurality of pads 12 with different specifications to a corresponding height to match the deflection of the vertical plate 1 to produce the deflection. The two ends in the middle of the lower cover plate 2 are both clamped tightly by the pressing block 9.

[0051] In this embodiment, one side of the lower cover plate 2 abuts closely against the side positioning tooling 5 to ensure straightness. Taking the center of the lower cover plate 2 as the reference, pads 12 of 30*900 mm are respectively padded at the center of the lower cover plate 2 and at positions 2500 mm and 5000 mm away from the center, and the thicknesses are 50 mm, 42 mm, and 22 mm respectively, for a total of five places, as Figure 12 shown; at points a and b at the bending part of the lower cover plate 2, it is required to use the pressing block 9 to clamp the lower cover plate 2 and the platform tightly to prevent the lower cover plate from causing deformation of the box girder.

[0052] (4) Group welding of the vertical plate 1, the lower cover plate 2, and the partition plate 4: Adjust the straightness and perpendicularity of the side positioning tooling 5 on the left side. Taking the side positioning tooling 5 on the left side as the reference, the left vertical plate 1 and the partition plate 4 are positioned in combination with the spacer block 8, and the left vertical plate 1 and the partition plate 4 are spot-fixed. Use a square to ensure that the perpendicularity of the vertical plate 1 and the partition plate 4 is not more than 1 mm; then, the right vertical plate 1 is positioned with the partition plate 4 and the lower cover plate 2. The right vertical plate 1 is clamped tightly through the plurality of side positioning toolings 5 and the side positioning jack 10 on the right side to ensure the perpendicularity of the vertical plate and the open dimension between the two vertical plates, and the right vertical plate 1 and the partition plate 4 are spot-fixed. When spot-fixing the partition plate 4, it is spot-fixed from the middle to both sides; the production process is as Figures 13-15 shown.

[0053] (5) Welding of the inner weld seam of the box girder: To prevent overturning deformation, the box girder remains in the position of the previous process. The vertical welding is used for the weld seam between the diaphragm 4 and the vertical plate 1. The welding sequence is that two welders weld simultaneously from the middle to both sides; the welding sequence of the inner weld seam of the box girder is as Figure 16 shown.

[0054] (6) Spot welding of the upper cover plate 3: After using the overhead crane to hoist the upper cover plate 3 onto the box girder, fine-tune the dimensions in the front, back, left, and right directions to meet the drawing requirements. When the gap between the upper cover plate 3 and the vertical plate 1 is ≥ 3 mm, use the upper positioning jack 11 and the upper support tooling 6 to press firmly, and then perform spot welding from the middle of the vehicle frame to both sides;

[0055] (7) Welding of the outer weld seam of the box girder: Remove the side positioning tooling 5 on one side, use the overhead crane to turn the box girder 90°, and four people weld simultaneously from the middle of the vehicle frame to both ends. Use multi-layer continuous welding, and clean the welding slag and surface spatter in time after each layer of weld bead is welded.

[0056] Weld according to the Figure 17 shown welding sequence. It is necessary to wait until the temperature of the weld seam cools down to room temperature before flipping. It is strictly prohibited to weld one side of the weld seam completely and then weld the other side.

[0057] (8) Grinding: After welding, tidy up and grind to clean the welding slag and spatter.

[0058] In view of the two major difficulties of welding deformation control and deflection production in the manufacture of large vehicle frame box girders, this invention makes convenient tooling during the manufacture of the box girder, strictly requires the quality of materials and assembly gaps, optimizes welding parameters and welding sequences to ensure that the finished product of this box girder meets the drawing requirements, and solves the problem of difficult production of large-deflection and large box girders widely used in rail vehicles and large track maintenance machinery; the successful manufacture of this box girder improves the operation level of workshop workers, enriches the on-site experience of process personnel and workshop workers, and lays a foundation for the subsequent manufacture of other large steel structures.

[0059] For those skilled in the art, it is obvious that this invention is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or basic characteristics of this invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of this invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in this invention. Any reference signs in the claims should not be regarded as limiting the claimed rights.

[0060] In addition, it should be understood that although this specification is described in terms of embodiments, not every embodiment contains only one independent technical solution. This narrative manner of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A manufacturing method for a large box girder of a vehicle frame, characterized in that: The box beam is welded together from two vertical plates (1), a lower cover plate (2), an upper cover plate (3) and a plurality of partition plates (4); specifically comprising the following steps: (1) Tool preparation: making a plurality of side positioning tools (5), a plurality of upper support tools (6) and two lower support tools (7), and preparing a plurality of cushion blocks (8), a plurality of pressure blocks (9), a plurality of side positioning jacks (10), a plurality of upper positioning jacks (11) and pads (12) of various specifications; (2) Cutting: Cutting the vertical plate (1), the lower cover plate (2), the upper cover plate (3) and the partition plate (4) according to the dimensions required by the drawings, and the vertical plate (1) is prefabricated with deflection in the middle part when cutting; (3) Making the deflection of the lower cover plate (2): a plurality of side positioning fixtures (5) are evenly distributed in a row on the left side of the working platform, a long side of the lower cover plate (2) is close to the plurality of side positioning fixtures (5) on the left side, the lower parts of both ends of the lower cover plate (2) are supported by lower supporting fixtures (7), the middle part of the lower cover plate (2) is padded with a plurality of pads (12) of different specifications to a corresponding height to match the deflection of the vertical plate (1) to make the deflection, and both sides of the two ends of the middle part of the lower cover plate (2) are pressed by pressing blocks (9); (4) Assembling and welding the vertical plate (1), the lower cover plate (2) and the partition plate (4): adjusting the straightness and verticality of the side positioning fixture (5) on the left side, taking the side positioning fixture (5) on the left side as a reference, and positioning the vertical plate (1) and the partition plate (4) on the left side in combination with the cushion block (8), and spot-fixing the vertical plate (1) and the partition plate (4) on the left side, and using a square to ensure that the verticality of the vertical plate (1) and the partition plate (4) is ≯1mm; then, the partition plate (4) and the lower cover plate (2) are used to locate the vertical plate (1) on the right side, and the verticality of the vertical plate and the opening size of the two vertical plates are pressed by multiple side positioning fixtures (5) and side positioning jacks (10) on the right side. The vertical plate (1) and the partition plate (4) on the right side are spot-fixed, and the partition plate (4) is spot-fixed from the middle to both sides; (5) Welding of the inner side weld of the box beam: The box beam maintains the position of the previous process unchanged, and the welds of the partition plate (4) and the vertical plate (1) are welded vertically. The welding sequence is to weld from the middle to both sides at the same time; (6) Spot fixation of the upper cover plate (3): After the upper cover plate (3) is hoisted onto the box beam using an overhead crane, the front, rear, left, and right dimensions are fine-tuned to the requirements of the drawing. When the gap between the upper cover plate (3) and the vertical plate (1) is ≥3 mm, the upper positioning jack (11) and the upper support fixture (6) are used to press the upper cover plate (3) and then spot fixation is performed from the middle of the frame to both sides. (7) Welding of the outer weld of the box beam: remove the side positioning tool (5) on one side, use the overhead crane to flip the box beam 90 degrees, and four people weld from the middle of the frame to both ends at the same time, using multi-layer continuous welding. After each layer of welding is completed, clean the welding slag and surface spatter in time; (8) Grinding: After welding, clean up the welding slag and spatter by grinding.

2. The manufacturing method of a large box girder for a vehicle frame according to claim 1, characterized in that: In the above step (2), the prefabricated deflection value of the vertical plate (1) is 50 mm when the vertical plate (1) is cut, and the deflection production range is the middle straight line section that matches the lower cover plate (2).

3. The manufacturing method of a large box girder of a vehicle frame according to claim 1, characterized in that: In the above step (2), the vertical plate (1), the lower cover plate (2) and the upper cover plate (3) are respectively formed by splicing three pieces of plates; among them, in order to prevent bending deformation at the splicing joints, the lower cover plate (2) and the upper cover plate (3) are spliced with 40-mm-thick plates and completed by the welding method of less welding and more turning over; the vertical plate (1) is spliced with 20-mm conventional plates, and the side positioning tooling (5) and the upper support tooling (6) are used in combination with the upper positioning jack (11) and the pressing block (9) to clamp the splicing joints.

4. The manufacturing method of a large box girder of a vehicle frame according to claim 1, characterized in that: In the above step (3), one side of the lower cover plate (2) is closely attached to the side positioning tooling (5) to ensure straightness. Taking the center of the lower cover plate (2) as the reference, pads (12) of 30*900 mm are respectively placed at the center of the lower cover plate (2) and at positions 2500 mm and 5000 mm away from the center, and the thicknesses are 50 mm, 42 mm and 22 mm respectively; at points a and b at the bending part of the lower cover plate (2), the pressing block (9) is used to press the lower cover plate (2) against the platform to prevent the lower cover plate from causing deformation of the box girder.

5. The manufacturing method of a large box girder of a vehicle frame according to claim 1, characterized in that: In the above step (1), each of the side positioning toolings (5) includes two vertically arranged columns (5-1), the lower ends of the two columns (5-1) are connected by a lower cross beam (5-4), the upper ends of the two columns (5-1) are connected by an upper cross beam (5-2), the two columns (5-1) are connected by an inclined beam (5-3), and the inside of the column (5-1) is strengthened and connected by a rib plate (5-5); a hole is provided at the upper end of the column (5-1) for the end of the upper support tooling (6) to pass through for positioning.

6. The manufacturing method of a large box girder for a vehicle frame according to claim 1, characterized in that: In the above step (1), the upper support tooling (6) is formed by symmetrically buckling and connecting two channel steels (6-1), and the two channel steels (6-1) are connected by an internal rib plate (6-2).

7. The manufacturing method of a large box girder for a vehicle frame according to claim 1, characterized in that: In the above step (1), the lower support tooling (7) includes upper and lower cover plates (7-1) that are parallel and corresponding to each other up and down, and the upper and lower cover plates (7-1) are connected by a plurality of support ribs (7-2).

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