A method for controlling the flatness of window panels on side walls of subway vehicles

Abstract

The invention discloses a method for controlling the flatness of a side wall window panel of a subway vehicle. The side wall is welded while avoiding the area near the window. Before the welding process of the side wall and the roof, prefabricated reverse deformation is applied to the side wall and the roof respectively, the adjustment range of the width of the body section size is (-2, 0) mm, the adjustment range of the body height is (+8, +10) mm, the adjustment range of the side wall outer contour is (+2, +3) mm, the adjustment range of the roof outer contour is +3 mm, the roof width size is adjusted to (-2, 0) mm, the side wall height size is adjusted to (+5, +7) mm, and the flatness of the window panel before the body welding is 1.5 mm / m. According to the prediction analysis of the welding deformation trend of the body synthesis process, the invention optimizes and improves the manufacturing tolerances of the side wall, the roof and other components in advance, reduces the deformation influence of the welding stress generated by the external force applied by the horizontal and oblique support tooling in the body synthesis process on the side wall window panel, finally reduces the adjustment amount of the body window panel and the out-of-tolerance area after welding, and shortens the body manufacturing cycle.

Description

Technical Field

[0001] The invention relates to the technical field of track manufacturing, and in particular to a method for controlling the flatness of a side wall window panel of a subway vehicle. Background Art

[0002] With the rapid development of the rail manufacturing industry, people have put forward higher requirements for the comfort, safety, speed and environmental protection of transportation. Aluminum and aluminum alloy profiles have gradually become the preferred raw materials for rail vehicle bodies due to their low density, high strength, good plasticity, easy forming, good electrical conductivity, thermal conductivity and corrosion resistance. In order to increase the operating speed of vehicles and facilitate people's daily travel, the lightweighting of aluminum alloy bodies has been further studied. However, the thinning of profiles will inevitably cause difficulties in the manufacturing process.

[0003] For existing rail transit vehicles, the lightweighting of the car body is mainly achieved by thinning the wall thickness of the side wall large component profile structure. The external profile of the side wall window panel is reduced from the traditional profile wall thickness of 3.3mm to 2.8mm, and the internal rib plate cavity is also reduced from the traditional 8-9 to the current 7. In addition, the window size is large, and the overall strength and rigidity of the side wall window panel area are weakened. As a result, during the assembly and welding process of the major components of the car body, the flatness of the window panel exceeds the 2mm / m standard required by the drawings, and the outer plane of the window panel basically collapses into the car.

[0004] The existing technical solution is to manufacture the major parts of the car body including the height and contour size of the side wall, the width and contour size of the roof in accordance with the tolerance requirements of the design drawings, and finally assemble and weld them with the chassis in the car body synthesis process. According to the theoretical analysis of the shrinkage deformation of the car body welding, the height, width and side wall contour direction of the car body section are pre-deformed before welding. After welding, conventional mechanical and flame adjustment measures are taken for the parts that exceed the tolerance, which can finally ensure that the product size meets the design standards. The main problems are as follows:

[0005] 1. The wall thickness of the profile in the window panel area of ​​the side wall component is relatively thin, and the heat input of the full-length weld is relatively large, which will cause significant deformation of the weld in the window panel area and the surrounding parent material. Although the size requirements of the component can be met through post-weld adjustment, the strength of the parent material is reduced after multiple adjustments. After the adjustment, there is still slight heat wave deformation in the window panel area and the parent material near the weld, which affects the aesthetics of the vehicle;

[0006] 2. Due to the large manufacturing tolerance range of each large component, the consistency of the product is poor. This will also lead to poor matching of the large components in the body assembly process. In this way, in the body assembly process, after the large components are assembled, there are various combinations of body cross-sectional dimensions, and the prefabricated reverse deformation also has a large adjustment amount. The above combined factors lead to poor consistency of the cross-sectional dimensions of the body after welding, and also increase the difficulty of controlling the flatness quality of the window panel after welding;

[0007] 3. Although most car bodies can meet the design standard requirements through post-welding adjustment, the increase in the number of adjustments will have a certain impact on the strength of the parent material, and some products may not meet the design size requirements after adjustment, and release will be taken when necessary. Through statistical analysis, the existing technical solutions require an average adjustment time of 12-16 hours for a single car body, and the product post-welding inspection pass rate is only about 70%, which seriously restricts the production efficiency and product quality of car body manufacturing, and has a certain impact on the subsequent window installation process.

[0008] In order to ensure the flatness quality requirement of window panels on the side walls of a vehicle body, the present invention provides a method for controlling the flatness of window panels on the side walls of a subway vehicle. Summary of the invention

[0009] The purpose of the present invention is to provide a method for controlling the flatness of the side wall window panels of a subway vehicle, so as to reduce the deformation influence of the side wall window panels, and finally reduce the amount of adjustment and repair of the vehicle body window panels and their out-of-tolerance areas after welding, thereby shortening the vehicle body manufacturing cycle.

[0010] To achieve the above object, the present invention provides the following solutions:

[0011] A method for controlling the flatness of a side wall window panel of a subway vehicle comprises the following steps:

[0012] Weld the side walls and avoid welding near the windows (add pictures);

[0013] Before the welding process of the side wall and the roof, the side wall and the roof are respectively subjected to prefabricated reverse deformation, the width of the body section is adjusted to (-2, 0) mm, the height of the body is adjusted to (+8, +10) mm, the outer bulge adjustment range of the side wall outer contour is (+2, +3) mm, the outer bulge adjustment range of the roof outer contour is +3 mm, the roof width is adjusted to (-2, 0) mm, the side wall height is adjusted to (+5, +7) mm, and the flatness of the side wall window panel before the body welding is 1.5 mm / m;

[0014] After the side wall and the roof are welded and installed with the chassis, a subway vehicle frame is obtained, and the flatness of the side wall window panels is obtained to be 2 mm / m or less.

[0015] Preferably, the theoretical tolerance of the adjustment range of the width of the body section dimension is (-4, +2) mm, the theoretical tolerance of the adjustment range of the body height is (-2, +6) mm, the theoretical tolerance of the adjustment range of the side wall height is (+3, +7) mm, the theoretical tolerance of the outer drum adjustment range of the side wall outer contour is (-2, +2) mm, the theoretical tolerance of the outer drum adjustment range of the roof outer contour is (-3, +3) mm, and the theoretical tolerance of the roof width adjustment range is (-4, +2) mm.

[0016] Preferably, before the roof and the side walls are welded, longitudinal supports, horizontal supports and diagonal supports are arranged inside the subway vehicle frame formed by the side walls, the roof and the underframe.

[0017] Compared with the prior art, the present invention has achieved the following technical effects:

[0018] 1. The present invention optimizes and improves the manufacturing tolerances of side walls, roofs and other components in advance based on the prediction and analysis of the welding deformation trend in the vehicle body assembly process, reduces the deformation influence of the welding stress generated by the external force applied by the horizontal and oblique support tooling in the vehicle body assembly process on the side wall window panels, and ultimately reduces the amount of adjustment and repair of the vehicle body window panels and their out-of-tolerance areas after welding, thereby shortening the vehicle body manufacturing cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0020] Figure 1 It is a schematic diagram of the method flow of the present invention;

[0021] Figure 2 It is a schematic diagram of the deformation trend of the side wall and the roof after welding of the present invention;

[0022] Figure 3 This is a schematic diagram of the deformation trend of prefabrication before welding of the present invention;

[0023] Figure 4 Schematic diagram of side wall welding;

[0024] Among them, 1. weld; 2. deformation trend after welding; 3. prefabrication deformation trend before welding; 4. window area; 5. weld. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] The purpose of the present invention is to provide a method for controlling the flatness of the side wall window panels of a subway vehicle, so as to reduce the deformation influence of the side wall window panels, and finally reduce the amount of adjustment and repair of the vehicle body window panels and their out-of-tolerance areas after welding, thereby shortening the vehicle body manufacturing cycle.

[0027] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0028] refer to Figures 1 to 3A method for controlling the flatness of side wall window panels of a subway vehicle comprises the following steps: welding the side wall and avoiding the area near the window for welding; applying prefabricated reverse deformation to the side wall and the roof respectively before the welding process of the side wall and the roof, adjusting the width of the car body section size to (-2, 0) mm, adjusting the height of the side wall to (+8, +10) mm, adjusting the outer bulge of the side wall outer contour to (+2, +3) mm, adjusting the outer bulge of the roof outer contour to +3 mm, and the flatness of the side wall window panels before the car body is welded is 1.5 mm / m; welding the side wall and the roof and installing them with the chassis to obtain a subway vehicle frame, and obtaining the flatness of the side wall window panels to be 2 mm / m or less; the invention optimizes the welding method of the side wall components by analyzing the structures of the existing major components of the car body, and does not weld the welds in the processing area of ​​the side wall window, thereby reducing the deformation effect of the welding heat input on the mother material of the window panels. At the same time, according to the anti-deformation data of the body section prefabricated in the body synthesis process, the side wall height, contour, roof width and contour dimensions that affect the body section are controlled within the tolerance range required for body synthesis in advance during the assembly and welding of the side wall and roof. The use of cross and oblique supports to impose anti-deformation constraints on the body section by external force is reduced or eliminated, thereby reducing the impact of the welding internal stress generated by the external force constraint on the flatness of the side wall window panel after the release, and achieved good results: the welding of the weld in the window panel area is eliminated. The welding time is reduced and the cost of welding materials is saved. Generally, there are about 6-8 side wall windows of a subway vehicle, and the weld length of each window is about 3 meters, with a total weld length of about 24 meters. The welding cost is saved by at least 20,000-30,000 yuan / vehicle, and the welding time is shortened by at least 120-150 minutes / vehicle; the flatness of the window panels of the vehicle body is reduced from the original 3-4mm / m to 2.5-2mm / m, and most of the window panels are controlled within the design requirement range of 2mm / m, reducing the amount of vehicle body adjustment or even eliminating adjustment. According to statistics, after adopting the technical solution of the present invention, the qualified rate of vehicle body inspection is increased from the original 70% to more than 95%, and the product quality is greatly improved. The adjustment time of the window panels of a single vehicle is reduced from the original 12-16 hours to 2-3 hours. While greatly shortening the production cycle, the labor cost and energy consumption are also significantly reduced. The labor cost and energy consumption of a single vehicle are reduced by about 30,000 yuan.

[0029] Furthermore, the theoretical tolerance of the adjustment range of the width of the body section dimension is (-4, +2) mm, the theoretical tolerance of the adjustment range of the body height is (-2, +6) mm, the theoretical tolerance of the adjustment range of the side wall height is (+3, +7) mm, the theoretical tolerance of the outer drum adjustment range of the side wall outer contour is (-2, +2) mm, the theoretical tolerance of the outer drum adjustment range of the roof outer contour is (-3, +3) mm, and the theoretical tolerance of the roof width adjustment range is (-4, +2) mm.

[0030] Furthermore, before the roof and the side walls are welded, longitudinal supports, horizontal supports and diagonal supports are arranged inside the subway vehicle frame formed by the side walls, the roof and the underframe.

[0031] Adaptive changes made according to actual needs are all within the protection scope of the present invention.

[0032] It should be noted that it is obvious to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be regarded as exemplary and non-restrictive from any point of view, and the scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims are included in the invention. Any reference numeral in a claim should not be regarded as limiting the claim to which it relates.

Claims

1. A method for controlling the flatness of window panels on side walls of subway vehicles, characterized in that: The following steps are involved: Weld the side walls and avoid welding near the windows; Before the welding process of the side wall and the roof, the side wall and the roof are respectively subjected to prefabricated reverse deformation, the width of the body section is adjusted to -2mm to 0mm, the height of the body is adjusted to 8mm to 10mm, the outer bulge of the side wall outer contour is adjusted to 2mm to 3mm, the outer bulge of the roof outer contour is adjusted to 3mm, the width of the roof is adjusted to -2mm to 0mm, the height of the side wall is adjusted to 5mm to 7mm, and the flatness of the side wall window panel before the body welding is 1.5mm / m; After welding the side wall and the roof and installing them with the chassis, a subway vehicle frame is obtained, and the flatness of the side wall window panel is obtained to be 2 mm / m or less; Before the roof and the side walls are welded, longitudinal supports, horizontal supports and diagonal supports are arranged inside the subway vehicle frame formed by the side walls, the roof and the underframe.

2. A method for controlling the flatness of window panels on side walls of subway vehicles according to claim 1, characterized in that: The adjustment range of the width of the body section dimension is -4mm to 2mm, the adjustment range of the body height is -2mm to 6mm, the adjustment range of the side wall height is 3mm to 7mm, the outer bulge adjustment range of the side wall outer contour is -2mm to 2mm, the outer bulge adjustment range of the roof outer contour is -3mm to 3mm, and the roof width adjustment range is -4mm to 2mm.

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