Method for preparing a power supply vehicle compartment

Abstract

The present invention relates to a method for preparing a carriage of a power supply vehicle, comprising the following steps: S1, welding the chassis assembly, front panel, rear panel, left panel, right panel and roof of the carriage to form a carriage frame; S2, cutting the plate according to the size of the carriage frame to form a mask to be connected to the carriage frame; S3, marking the area corresponding to the carriage frame on the mask as a first bonding surface, and the outer surface of the carriage frame as a second bonding surface; S4, cleaning the first bonding surface and the second bonding surface, roughening them, and evenly applying an adhesive primer on the first bonding surface and the second bonding surface; S5, after the adhesive primer is dried, evenly applying an adhesive on the second bonding surface, and attaching the mask to the corresponding carriage frame so that the adhesive is filled between the first bonding surface and the second bonding surface for bonding; S6, hemming and cornering the edges of the carriage to obtain the power supply vehicle carriage.

Description

Technical Field

[0001] The present invention relates to the field of power supply vehicles, and in particular to a method for preparing a carriage of a power supply vehicle. Background Art

[0002] Power supply vehicles are power emergency equipment, customized and developed according to the needs of customers in different regions. They have been extended from the original single fuel generator power supply vehicle to UPS power supply vehicles, hydrogen fuel power supply vehicles, flywheel UPS power supply vehicles and semi-trailer power supply vehicles. They are equipped with battery packs, inverters, etc. and are used as power emergency equipment in different locations.

[0003] The main body of the original power car body adopts the method of base beam + frame (40# square tube) to improve the structural strength of the car body. This structure not only has a high investment cost for car body production, but also as the length of the car body increases, the number of frame profiles and welding increases, and the corresponding vehicle weight increases; and the welding process causes the thermal deformation of the outer cover plate to increase the impact on the flatness of the car body; the deformation deviation of the car body flatness directly affects the increase in production cost of the next painting process. The original car body welding process is not only labor-intensive and low in production efficiency, but also has high production cost for the entire car body, and the amount of paint scraping increases, resulting in a significant increase in vehicle after-sales maintenance costs.

[0004] The purpose of this invention is to design a method for preparing a power supply vehicle compartment in response to the above-mentioned problems in the prior art. Summary of the Invention

[0005] In response to the problems existing in the above-mentioned prior art, the present invention provides a method for preparing a compartment of a power supply vehicle, which can effectively solve at least one problem existing in the above-mentioned prior art.

[0006] The technical solution of the present invention is:

[0007] A method for preparing a power supply vehicle compartment comprises the following steps:

[0008] S1, weld and align the chassis assembly, front panel, rear panel, left panel, right panel, and roof of the carriage to form the carriage frame;

[0009] S2, cutting the plate according to the size of the carriage frame to form a mask to be connected to the carriage frame;

[0010] S3, marking the area corresponding to the vehicle frame on the mask as a first bonding surface, and using the outer surface of the vehicle frame as a second bonding surface;

[0011] S4, cleaning and roughening the first adhesive surface and the second adhesive surface, cleaning and drying them again, and evenly applying an adhesive primer on the first adhesive surface and the second adhesive surface;

[0012] S5, after the adhesive primer is dry, evenly apply adhesive on the second adhesive surface, and attach the mask to the corresponding vehicle frame so that the adhesive fills the space between the first adhesive surface and the second adhesive surface to bond them together;

[0013] S6, gaps between adjacent panels are filled to form a carriage, and edges and corners of the carriage are hemmed to obtain a power supply carriage.

[0014] Furthermore, marking the area corresponding to the vehicle frame on the mask as the first bonding surface includes:

[0015] Aligning the mask to a corresponding position on the periphery of the carriage frame;

[0016] A border line is drawn on the mask along the border of the carriage frame using a marker pen, and the area framed by the border line on the mask is used as the first bonding surface.

[0017] Furthermore, in step S4, according to the hardness of the carriage frame and the panel, the higher the hardness, the smaller the grit of sandpaper is selected for roughening.

[0018] Furthermore, the carriage frame is made of steel, the mask is made of aluminum, the first bonding surface is roughened with 60# sandpaper, and the second bonding surface is roughened with 40# sandpaper, so that the first bonding surface and the second bonding surface have uniform roughness.

[0019] Furthermore, evenly applying glue on the second bonding surface includes: beveling a nozzle of a glue gun to form a V-shaped opening, and applying glue in an S-shaped pattern on the second bonding surface through the nozzle with the V-shaped opening using a glue gun.

[0020] Furthermore, the skeleton is distributed with equal-height blocks, and the equal-height blocks are used to control the thickness of the adhesive.

[0021] After the mask is attached to the corresponding car frame, the mask fills the glue between the first bonding surface and the second bonding surface before bonding, including: covering the outside of the mask with a pressing plate, tightening and fixing the mask and the car frame with a clamp, so that the mask and the frame are in close contact.

[0022] Furthermore, the adhesive is made by adding charged particles to a two-component polyurethane adhesive. After the cover plate and the vehicle frame are tightened and fixed by a clamp so as to make close contact between the cover plate and the frame, the method further comprises:

[0023] A periodically reversed DC voltage is applied between the mask and the frame to generate a periodically reversed electric field between the mask and the car frame, so that the charged particles drive the adhesive to move back and forth under the action of the periodically reversed electric field, thereby evenly filling the space between the mask and the frame.

[0024] Furthermore, after step S6, the following steps are included:

[0025] S7, assembling doors and / or windows and / or locks on the carriage to obtain a power supply carriage.

[0026] Furthermore, in step S7, assembling the door body and / or window body on the carriage includes:

[0027] Apply adhesive to the outer side of the door and / or window frame folding member, press and bond the outer side of the door and / or window frame folding member to the carriage frame,

[0028] The inner sides of the frame folds of the door body and / or window body are welded to the carriage frame.

[0029] Furthermore, after the mask is attached to the corresponding vehicle frame, the adhesive is filled between the first bonding surface and the second bonding surface before bonding, including:

[0030] The mask is tapped to squeeze out the air between the first adhesive surface and the second adhesive surface.

[0031] Therefore, the present invention provides the following effects and / or advantages:

[0032] This application assembles the car body frame and panel by bonding. During the on-site sheet metal bonding process, the flatness requirements of the car body side are guaranteed, and the cost of painting and scraping in the next process is reduced; it is determined whether gluing can be used to replace the existing welding process to improve the deformation of the panel caused by welding; the lightweight design improves the overall performance of the power supply vehicle system and improves environmental protection requirements.

[0033] This application changes the traditional welding method by gluing, improving the traditional welding point connection to a surface connection, greatly improving the overall performance of the power compartment made by this application. It achieves the improvement of the flatness of the compartment appearance and the sheet metal production process, reduces production costs, reduces labor intensity, and meets environmental protection requirements; under the premise of ensuring the strength and safety performance of the vehicle compartment, the aluminum skin and skeleton structural parts are bonded together to reduce the curb weight of the vehicle as much as possible, thereby improving the vehicle's power, reducing fuel consumption, and reducing emission pollution. Due to the needs of environmental protection and energy conservation, the lightweighting of automobiles has become a trend in the development of the world's automobiles, and the improvement of the lightweight design of vehicles is required.

[0034] The present application adds charged particles to the adhesive, which can be driven by the electric field to drive the adhesive to move, and finally the adhesive is evenly and better contacted with the bonding surface, and the thin layer of air between the bonding surface and the adhesive is discharged, thereby further improving the performance of the car body after bonding.

[0035] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 Schematic diagram of an embodiment of the present invention.

[0037] Figure 2 This is a structural diagram of the carriage frame.

[0038] Figure 3 for Figure 2 side view.

[0039] Figure 4 This is a schematic diagram of the mask obtained by cutting the plate according to the size of the car frame.

[0040] Figure 5 This is a schematic diagram of the structure of one of the masks.

[0041] Figure 6 A schematic diagram showing the area corresponding to the carriage frame after marking one of the masks.

[0042] Figure 7 This is a schematic diagram of one of the masks after roughening.

[0043] Figure 8 Schematic diagram of one of the car body frames after adhesive application.

[0044] Figure 9 Schematic diagram of the nozzle.

[0045] Figure 10 Schematic diagram of the state where charged colloid particles move when an electric field is applied. DETAILED DESCRIPTION

[0046] In order to facilitate understanding by those skilled in the art, the present invention will now be described in further detail with reference to the accompanying drawings:

[0047] refer to Figure 1 A method for preparing a power supply vehicle compartment comprises the following steps:

[0048] S1, welding and aligning the chassis assembly, front panel, rear panel, left panel, right panel, and roof of the carriage to form the carriage frame 1;

[0049] In this embodiment, before step S1, the following can be performed: all door (window) frames are cut at 45° diagonally, and a single-side bevel of 2mm x 30° is required before welding the frame, and the butt gap is ≤0.5mm. The weld is smoothed after welding to remove welding defects such as cold welds, air holes, and undercuts. Then, a 5-ton crane is used to lift each frame assembly, and the four corners of the roof assembly are flush with the front and side frame edges of the compartment body, and are fixed by spot welding in sequence according to the process technology requirements such as welding current and voltage to obtain the required height and length dimensions. Next, the left and right side frame frames are corrected: the verticality of the left and right side frame frames is ensured to be within 2mm. As shown in the following figure: Figure 2-3 The carriage frame is shown.

[0050] This step is prior art and does not involve the core improvement points of this application.

[0051] S2, cutting the plate according to the size of the part of the carriage frame 1 to form a mask to be connected to the carriage frame;

[0052] In this step, the blanking size of the panel is calculated according to the size of the carriage frame part where the panel is required, and the panel is cut using a shearing machine according to the calculated size; and the panel meets the following requirements: 1) the panel is made of a whole plate; 2) the outer dimensions of the panel are not greater than the outer dimensions of the carriage frame. Figure 4-5 The mask shown.

[0053] S3, marking the area corresponding to the vehicle frame 1 on the mask 2 as the first bonding surface 201, and the outer surface of the vehicle frame as the second bonding surface 101;

[0054] The mask is fitted to the corresponding skeleton, and the alignment and positioning are adjusted. Use a marker to draw the boundary line of the skeleton rectangle. After the boundary line is drawn, Figure 6 As shown, the mask and skeleton are marked accordingly and placed in the specified positions.

[0055] S4, cleaning and roughening the first adhesive surface 201 and the second adhesive surface 101, cleaning and drying them again, and evenly applying an adhesive primer on the first adhesive surface and the second adhesive surface;

[0056] The roughening process can be done by sandpaper friction, abrasive friction, etc., and the first bonding surface is obtained as follows Figure 7The results are shown. Before roughening, clean and level any excess welds on the interface between the frame and the panel. Level any severely deformed areas of the frame after welding before applying the adhesive primer. After roughening, clean the surface dust first, then wipe the roughened areas of the frame and panel with ethyl acetate. After polishing, clean the surface within 4 hours to prevent re-oxidation, which could affect adhesive adhesion. After cleaning the polished surface, wait until the cleaning agent has dried before proceeding to the next step. Drying the cleaning agent varies depending on the season: 15 minutes below 30°C and 10 minutes above 30°C.

[0057] Use a wiping cloth (cotton cloth) to dip in the glass bonding primer to increase the bonding between the glass and the polyurethane. Apply the primer to the bonding surface of the mask and the inner frame to ensure that all bonding parts are evenly coated with the primer.

[0058] S5, after the adhesive primer is dry, evenly apply adhesive on the second adhesive surface, and attach the mask to the corresponding vehicle frame so that the adhesive fills the space between the first adhesive surface and the second adhesive surface to bond them together;

[0059] In this embodiment, polyurethane adhesive is selected and glue is applied on the frame using a pneumatic glue gun. 2mm is filled between the frame and the mask. The glue can fill the bonding surface with little or no exposed glue. Figure 8 The result shown is that the glue is glued on the center axis of the rectangular tube.

[0060] The polyurethane adhesive absorbs moisture in the air to dry. To prevent the adhesive from drying out before the mask is applied, the time from applying the glue to bonding the mask should not be more than 20 minutes.

[0061] S6, gaps between adjacent panels are filled to form a carriage, and edges and corners of the carriage are hemmed to obtain a power supply carriage.

[0062] In this embodiment, a 3mm gap is left between the adjacent panels on the front, rear, left and right side panels, and modified silane sealant is used to fill the gaps. A modified silane sealant is also used to fill the 3mm gaps between the adjacent panels on the ceiling surface. After the glue is applied, the curing time is ≥72h, and the overflowed glue is repaired and the leaked parts are repaired.

[0063] After the panels are bonded, tap the panels lightly with a wooden or rubber hammer to prevent delamination, leaks, cracks, or dents. The joints between the panels and the frame should be sealed with glue.

[0064] Furthermore, marking the area corresponding to the vehicle frame on the mask as the first bonding surface includes:

[0065] Aligning the mask to a corresponding position on the periphery of the carriage frame;

[0066] A border line is drawn on the mask along the border of the carriage frame using a marker pen, and the area framed by the border line on the mask is used as the first bonding surface.

[0067] In this embodiment, the mask can be fixed by a fixture, a positioning tool, etc., so that it is aligned to the corresponding position of the outer periphery of the car frame, and then the operator draws the border line of the frame with a marker.

[0068] Furthermore, in step S4, according to the hardness of the carriage frame and the panel, the higher the hardness, the smaller the grit of sandpaper is selected for roughening.

[0069] Furthermore, the carriage frame is made of steel, the mask is made of aluminum, the first bonding surface is roughened with 60# sandpaper, and the second bonding surface is roughened with 40# sandpaper, so that the first bonding surface and the second bonding surface have uniform roughness.

[0070] In this step, the aluminum plate material is relatively soft and the steel frame material is relatively hard, so sandpaper with different roughness is required to achieve a certain surface roughness requirement so that the bonding surface exposes the corresponding roughness instead of scratches.

[0071] Furthermore, applying glue uniformly on the second bonding surface includes: beveling the nozzle 3 of the glue gun to form a V-shaped opening, and applying glue in an S-shaped pattern on the second bonding surface through the nozzle 3 with the V-shaped opening using the glue gun.

[0072] like Figure 9 As shown, the V-shaped nozzle 3 can effectively control the uniformity of the glue applied on the frame during the gluing process, so as to avoid uneven surface and quality problems of bonding firmness during subsequent masking.

[0073] Furthermore, the skeleton is distributed with contour blocks 4, and the contour blocks 4 are used to control the thickness of the adhesive.

[0074] After the mask is attached to the corresponding car frame, the mask fills the glue between the first bonding surface and the second bonding surface before bonding, including: covering the outside of the mask with a pressing plate, tightening and fixing the mask and the car frame with a clamp, so that the mask and the frame are in close contact.

[0075] In this step, 20x30mm 2mm / Q235 blocks of equal height are evenly spaced at 300mm intervals along the centerline of the rectangular tube of the car frame. These blocks will serve as leveling materials for the subsequent masking and as a limiter for the glue thickness. 2mm φ limiter material is then cut to the width of the frame, evenly spaced at intervals of 250-320mm. At this point, after the masking and car frame are tightened and secured with a clamp, a gap remains between them, which serves to retain the adhesive.

[0076] Furthermore, the adhesive 5 is made of a two-component polyurethane adhesive with charged particles added thereto. After the panel and the vehicle frame are tightened and fixed by a fixture so as to make close contact between the panel and the frame, the following steps are performed:

[0077] A periodically reversed DC voltage is applied between the mask and the frame to generate a periodically reversed electric field between the mask and the car frame, so that the charged particles drive the adhesive to move back and forth under the action of the periodically reversed electric field, thereby evenly filling the space between the mask and the frame.

[0078] Charged colloids utilize the adsorption properties of colloids. Colloidal particles have a large surface area and are charged by adsorption of ions or cations. Positively charged colloids include metal hydroxides and metal oxides, such as Al(OH)3 and Fe(OH)3, due to adsorption of their constituent cations. Negatively charged colloids include non-metallic oxides, metal sulfides, silicic acid, and soil colloids, such as H2SiO3 and As2S3, due to adsorption of their constituent anions. Charged colloids can move in a directional manner under the influence of an external electric field, approaching an electrode of opposite charge.

[0079] The present application adds charged particles to the two-component polyurethane adhesive because there is roughness on the bonding surface after roughening. After simple glue coating, there is a small amount of thin layer of air on the bonding surface, which makes it difficult for the adhesive to completely contact the bonding surface, and ultimately the bonding effect is poor. The addition of charged particles generates a periodically reversed electric field between the mask and the frame, so that the electric field cyclically circulates from the mask to the frame and from the frame to the mask. Under the action of the electric field, the charged particles periodically drive the adhesive toward the first bonding surface and toward the second bonding surface. Ultimately, the adhesive is evenly applied to the two bonding surfaces, making the final car body more solid, meeting the overall structural design of the power supply vehicle, and having high strength and good rigidity; at the same time, it can meet various performance indicators of the power during operation, ensuring the safety and reliability of the product during use and operation.

[0080] Furthermore, after step S6, the following steps are included:

[0081] S7, assembling doors and / or windows and / or locks on the carriage to obtain a power supply carriage.

[0082] Furthermore, in step S7, assembling the door body and / or window body on the carriage includes:

[0083] Apply adhesive to the outer side of the door and / or window frame folding member, press and bond the outer side of the door and / or window frame folding member to the carriage frame,

[0084] The inner sides of the frame folds of the door body and / or window body are welded to the carriage frame.

[0085] In this step, all exposed door (window) frames are welded and the side (rear) doors and blinds are installed;

[0086] The door (window) frame folding parts are welded to the inner side of the carriage frame and made with the outer side of the carriage frame using structural adhesive technology. The contact surface is required to be evenly coated with glue. During assembly, pre-open Φ4.1 rivet holes on the door frame to ensure that the countersink angle is 120°. The drilled holes must be perpendicular to the riveted surface. Use Φ4×16 countersunk blind rivets for tightening and reinforcement. The rivet spacing is required to be 300mm-500mm. The riveting positions are all in the center of the frame plate. After the blind rivets are riveted, the rivet caps must not be twisted; then crimping is performed. During crimping, the glue must overflow the edge of the door frame. After crimping, the overflowed glue is repaired and the leaked parts are repaired.

[0087] Furthermore, after the mask is attached to the corresponding vehicle frame, the adhesive is filled between the first bonding surface and the second bonding surface before bonding, including:

[0088] The mask is tapped to squeeze out the air between the first adhesive surface and the second adhesive surface.

[0089] Experimental data

[0090] Table 1, Connection strength test results (unit: kN)

[0091]

[0092] In summary, this embodiment assembles the car body frame and the panel by bonding. During the on-site sheet metal bonding process, the flatness requirements of the car body side are guaranteed, and the cost of painting and scraping in the next process is reduced; it is determined whether gluing can be used to replace the existing welding process to improve the deformation of the panel caused by welding; the lightweight design improves the overall performance of the power supply vehicle system and improves environmental protection requirements.

[0093] It should be noted that in the claims, any reference signs placed between parentheses shall not be construed as limiting the claims. The word "comprising" does not exclude the presence of components or steps not listed in the claim. The word "a" or "an" preceding a component does not exclude the presence of a plurality of such components. The invention can be implemented by means of hardware comprising several different components and by means of a suitably programmed computer. In a unit claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The use of the words first, second, third etc. does not indicate any order. These words may be interpreted as names.

[0094] Although the preferred embodiments of the present invention have been described, those skilled in the art may make additional changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0095] In the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," "connect," "fixed," etc. should be understood broadly. For example, they may refer to fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0096] In the description of this specification, the reference terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms should not be understood as necessarily referring to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and features of different embodiments or examples without contradiction.

Claims

1. A method for preparing a power supply vehicle compartment, characterized in that: The following steps are involved: S1, weld and align the chassis assembly, front panel, rear panel, left panel, right panel, and roof of the carriage to form the carriage frame; S2, cutting the plate according to the size of the carriage frame to form a mask to be connected to the carriage frame; S3, marking the area corresponding to the vehicle frame on the mask as a first bonding surface, and using the outer surface of the vehicle frame as a second bonding surface; S4, cleaning and roughening the first adhesive surface and the second adhesive surface, cleaning and drying them again, and evenly applying an adhesive primer on the first adhesive surface and the second adhesive surface; S5, after the adhesive primer has dried, evenly apply adhesive to the second adhesive surface, and attach the mask to the corresponding vehicle frame, so that the adhesive fills the space between the first adhesive surface and the second adhesive surface to bond them together; the frame is provided with contour blocks, which are used to control the thickness of the adhesive; After the mask is attached to the corresponding vehicle frame, the mask is filled with glue between the first bonding surface and the second bonding surface before being bonded, including: covering the outer side of the mask with a pressing plate, tightening and fixing the mask and the vehicle frame with a clamp to ensure close contact between the mask and the frame; The adhesive is made by adding charged particles to a two-component polyurethane adhesive. After the mask and the carriage frame are tightened and fixed by a clamp so as to make close contact between the mask and the frame, the method includes: Applying a periodically reversed DC voltage between the mask and the frame generates a periodically reversed electric field between the mask and the frame, so that the charged particles drive the adhesive to reciprocate under the action of the periodically reversed electric field, thereby evenly filling the space between the mask and the frame; S6, gaps between adjacent panels are filled to form a carriage, and edges and corners of the carriage are hemmed to obtain a power supply carriage.

2. The method for preparing a power supply vehicle compartment according to claim 1, characterized in that: Marking the area corresponding to the carriage frame on the mask as the first bonding surface includes: Aligning the mask to a corresponding position on the periphery of the carriage frame; A border line is drawn on the mask along the border of the carriage frame using a marker pen, and the area framed by the border line on the mask is used as the first bonding surface.

3. The method for preparing a power supply vehicle compartment according to claim 1, characterized in that: In step S4, according to the hardness of the carriage frame and the panel, the higher the hardness, the smaller the grit of sandpaper is selected for roughening.

4. The method for preparing a power supply vehicle compartment according to claim 3, characterized in that: The carriage frame is made of steel, the mask is made of aluminum, the first bonding surface is roughened with 60# sandpaper, and the second bonding surface is roughened with 40# sandpaper, so that the first bonding surface and the second bonding surface have uniform roughness.

5. The method for preparing a power supply vehicle compartment according to claim 1, characterized in that: Uniformly applying glue on the second bonding surface includes: beveling a nozzle of a glue gun to form a V-shaped opening, and applying glue in an S-shaped pattern on the second bonding surface through the nozzle with the V-shaped opening using a glue gun.

6. The method for preparing a power supply vehicle compartment according to claim 1, characterized in that: After step S6, the following steps are included: S7, assembling doors and / or windows and / or locks on the carriage to obtain a power supply carriage.

7. The method for preparing a power supply vehicle compartment according to claim 6, characterized in that: In step S7, assembling the door body and / or window body on the carriage includes: Apply adhesive to the outer side of the door and / or window frame folding member, press and bond the outer side of the door and / or window frame folding member to the carriage frame, The inner sides of the frame folds of the door body and / or window body are welded to the carriage frame.

8. The method for preparing a power supply vehicle compartment according to claim 1, characterized in that: After the mask is attached to the corresponding vehicle frame, the adhesive is filled between the first bonding surface and the second bonding surface before bonding, including: The mask is tapped to squeeze out the air between the first adhesive surface and the second adhesive surface.

Images